1. Install the following resistors:
- R2, R3, R4 - 1K ohm 0.25w
- R5 - 390R ohm 0.25w
- R6 - 10K ohm 0.25w
- R7 - 270R ohm 0.25w
- R8 - 470R ohm 0.25w
2. Intsall the recifiers (the black ones).
- D2, D3, D4 - 1N4001 - 50V 3A
3. Install the zener diodes (brown ones).
D1 - 9.1V 0.5w
4. Install capacitors.
C1, C2 - 0.1uF 50V
5. Install LED's, red in LED1, yellow in LED5, green in LED6.
The leds have to be installed on copper side so that they can be seen
when holes are put into plastic box.
6. Install jumper wire as shown in diagram.
7. Install IC chip LM324, note that there is a circle on the chip that should
line up with the notch on the board.
8. Strip 5-10mm of three wires (red, black and green) and twist the ends.
- Positive - red
- Negative - black
- o2 - green
9. Cut hole in box for the 3 wires wires to go through.
10. Check to see if your soldering is correct.
11. When the soldering is correct, put the 3 wires through the box and solder
them to the board.
12. Strip 5mm off the ends of the wires and place alligator clips on the ends of them.
13. Carefully place the cover onto the box and the o2 sensor is complete.
Fuel Pressure:
To check fuel pressure, what you do is hook up a fuel pressure gauage onto the fuel rail and turn the ignition on and check what the reading is.
Fuel Flow:
To check this, what you is undo a hose at the end of the fuel rail and get a catch can ready see how much furl comes out of the rail.
To test the injectors, what you need to do is test the voltage on them. after that, you need to remove them from the engine. the reason you do this is because you need to put them into an injector tester to inspect the spray pattern and smoothness of the spray. if the spray pattern isnt a triangular shape with mist like fuel coming out then it needs to be changed, also if the spray isnt smooth through the full injection it should be changed e.g. splutters instead of being smooth.
This is what the spray pattern should look like.
Injector Cleaning:
Vapour deposits from left over fuel can clog up the injectors, this can be cleaned with injector cleaners which contain fuel additives and detergents. However, these do not get rid of the problem. To keep them properly clean you need to clean them every 20,000-25,000 km.
To do this, you need to link the vehicle up with the exhaust gas analyser to measure the emissions coming out of the exhaust of the vehicle.
Standard numbers go as follows:
Hydro carbon = 1ppm (idle) and 5ppm (2500rpm)
Carbon Minoxide = 0.04% (idle) and 0.01% (2500rpm)
Carbon Dioxide = 15.5% (idle) and 15.4% (2500rpm)
o2 = 0.1% (idle ans 2500rpm)
Checking emissions on vehicles is important it shows what is being emitted out of the exhaust. This means that cars can be made more efficient and environmentally friendly in the future.
How do you time a
diesel engine? What do you need?- Firstly, you line the crank
shaft up to TDC.- Next, you put the gauge in
to the injection pump.- After that, rotate the crank
shaft backwards 30 degrees.- Turn the gauge to
0.- Rotate
the crank shaft forward to 2 degrees.- Check the reading on the
gauge, if it's within the manufactures specs then it's fine. If not, you have to
undo 2 bolts on the injection pump and move the unit forward or backward to get
it to manufactures specs.You need a socket set to undo
the bolts and rotate the crank shaft.
How do you bleed a
diesel engine?
- Crack each injector and
crank the engine over until fuel comes out of the injector.
What is the purpose of the Glow Plugs? How do you test them?
- The purpose of a glow plug is to heat the cylinder up so that it is hot enough for ignition.
- You can test with an Amp meter. You do this by placing one end of the amp meter to the top of the glow plug and the other end to the body of the glow plug (each glow plug should read 10 amps).
What's the difference between diesel and petrol engine?
- Both engines are constructed the same e.g. the design, however diesel engines do not have spark plugs to ignite the fuel. Instead they have glow plugs to heat up the cylinder before the car can be cranked over.
- Also, diesel engines are more heavy duty and last longer than petrol engines.
What are the 4 things to check on a non-start?
- Air: Oxygen surrounds us, so there will most likely be are present.
- Fuel: You can check if the injectors are injecting fuel into the cylinders.
- Heat: Check that the glow plugs are working and heat up quickly (between 5-10 seconds).
- Compression: Check the compression on all the cylinders. On a diesel engine the compression should be around 450-500 psi. To do this, take out the glow plug and put in a compression gauge. If it's not at 450-500 psi you should check to see if the head gasket or piston rings are broken.
How do you bleed a diesel engine?
- Crack each injector and crank the engine over until fuel comes out of the injector.
What is the Diesel Bug? How is it caused?
- The diesel bug is a build up of algae inside the fuel tank.
- It is caused by not having a full tank of fuel and then not running the engine for a long period of time e.g. 6 months. This happens because of condensation in side the fuel tank.
How does an injector work?
- It injects high pressure fuel into the cylinders. This happens because the fuel starts in the fuel tank, it then goes into the diesel pump and then into the fuel rail. As the fuel goes along, it has to fit into a smaller space every time. This builds up the pressure, by the time it gets to the injector it is at its highest pressure.
What is the purpose of an injector pump?
- The purpose of an injection pump is to make sure that the injector inject at the correct time. To make sure of this you have time the injection pump in time with the crank shaft.
How do you time a diesel engine? What do you need?
- Firstly, you line the crank shaft up to TDC.
- Next, you put the gauge in to the injection pump.
- After that, rotate the crank shaft backwards 30 degrees.
- Turn the gauge to 0.
- Rotate the crank shaft forward to 2 degrees.
- Check the reading on the gauge, if it's within the manufactures specs then it's fine. If not, you have to undo 2 bolts on the injection pump and move the unit forward or backward to get it to manufactures specs.
You need a socket set to undo the bolts and rotate the crank shaft.
What is the difference between a diesel and petrol piston?
- A diesel piston has a grove in the top to give maximum surface area for combustion. It also has slots on the sides that have rings in them to generate friction and in-turn extra heat.
This is a Diesel Piston
This is a Petrol Piston
How does a turbo work?
- On one side, the turbo takes the exhaust and spins it through its turbine to be released at a higher speed. On the other side, the turbo takes in cold air and pushes it into the inter-cooler to then be pushed into the intake side.
What is common rail?
- Common Rail injection is very similar to fuel injection on a petrol engine. It uses a very high pressure fuel rail that feeds individual injectors. The fuel rail has a pressure of about 15,000 psi.
