Chapter 6

Basic Engine Terminology and

Operating Principles
Measuring Torque Rise 6-1
Using a chassis
dynamometer or a vehicle
connected to a laptop with
OEM software, run the
vehicle through its entire
engine operating range
under load. Use a data
recorder or take
snapshots of the engine
data list during the trip
using the feature in the
OEM software.
Measuring Torque Rise 6-1
During a road test, a
vehicle that is lugged
by using a gear that is
one or two steps above
where it should operate
will move through peak
torque with a full throttle
application. Record the
trip using a data logger
feature within the OEM
software.
Measuring Torque Rise 6-1
Operate the vehicle at
highway speed one or
two gears down from
where it should be
while the vehicle is
under load, such as
traveling up a hill.
Again, record the
data.
Measuring Torque Rise 6-1
Find the highest peak
torque value
recorded.
Find the highest
torque value reached
while the engine was
at rated speed.
Measuring Torque Rise 6-1
Calculate the torque
rise using the
following formula:
(Peak Torque Rated
Torque/Rated Torque) x
100 = Torque Rise
Measuring Torque Rise 6-1
Determine whether
the torque rise is
more suited to
vocational or on-
highway use and
compare your findings
with the vehicles
actual application.
Performing a Stall Test 6-2
Warm the engine to
operating
temperature.
Chock the wheels
with purpose made
blocks and apply the
park brakes.
Performing a Stall Test 6-2
Using an appropriate
electronic service tool
or OEM software,
navigate to an engine
data display screen and
prepare a custom data
list including engine
rpm and boost
pressure. If fuel rates
and exhaust back
pressure are available,
measure those, too.
Performing a Stall Test 6-2
With the park brake
applied, depress the
accelerator until the
engine reaches its
maximum speed.
Observe and record
the engine rpm and
compare it to the
OEM specifications.
Engine rpm that is
Performing a Stall Test 6-2
lower than the OEM
specified rpm indicates
that the engine is not
producing enough
power.
Make service
recommendations to
investigate other
causes of low engine
power if the engine
stall speed
Performing a Stall Test 6-2
is more than 150 rpm
below the OEM
specifications.
Understanding Valve and Injector
Action in a Four-Stroke Cycle Diesel 6-3
Select an inline six
cylinder assembled
engine in the lab with
the valves correctly
adjusted and the
flywheel exposed.
Remove a valve
cover and identify the
intake and exhaust
rocker levers.
Understanding Valve and Injector
Action in a Four-Stroke Cycle Diesel 6-3
Using a shop manual,
OEM service information,
or other directions,
position the engine at
TDC for cylinder 1. The
use of timing pins,
aligning markers on the
front engine dampener,
flywheel, or accessory
drive pulley are just a few
of the many ways TDC
can be identified.
Understanding Valve and Injector
Action in a Four-Stroke Cycle Diesel 6-3
Use a piece of white
chalk to mark the bell
housing and the
flywheel at the 12
oclock position with
the engine at TDC.
Understanding Valve and Injector
Action in a Four-Stroke Cycle Diesel 6-3
Inspect the rocker levers
on cylinders 1 and 6.
One pair of levers should
both be tight and the
other pair loose. This
happens because one of
the cylinders is on valve
overlap while its paired
cylinder is ending
compression stroke and
beginning power stroke.
Understanding Valve and Injector
Action in a Four-Stroke Cycle Diesel 6-3
Rotate the engine in
the correct direction of
rotation using a (19
mm) bar and socket or
barring adapter
suitable to rotate the
engine. Have a partner
observe the operation
of the rocker levers on
one cylinder.
Understanding Valve and Injector
Action in a Four-Stroke Cycle Diesel 6-3
When rotating the engine
in the correct direction of
rotation, the exhaust valve
in the cylinder with both
valves closed should open
first within half of an engine
rotation. If the intake valve
opens first and more than
half of a rotation is needed,
the engine is being turned
in the wrong direction.
Understanding Valve and Injector
Action in a Four-Stroke Cycle Diesel 6-3
Any time valves and
injectors are adjusted, the
engine must be turned in
the correct direction of
rotation to adjust the
correct cylinder in its
proper valve position.
Failure to do this could
potentially result in
catastrophic engine
damage.
Understanding Valve and Injector
Action in a Four-Stroke Cycle Diesel 6-3
When the exhaust
valve just begins to
open, as indicated by
the disappearance of
exhaust valve lash,
mark the flywheel with
a chalk line and the
letters EO (for
exhaust opening).
Understanding Valve and Injector
Action in a Four-Stroke Cycle Diesel 6-3
Continue to rotate the
engine while observing
the exhaust valve and
note the point in the
rotation when it closes.
This is indicated by the
appearance of valve
lash. Mark the flywheel
with a chalk line and
the letters EC (for
exhaust closing).
Understanding Valve and Injector
Action in a Four-Stroke Cycle Diesel 6-3
Continue to rotate the
engine and observe the
intake valve opening and
closing. Mark the flywheel
with a chalk line and the
letters IO (for intake
opening) when the intake
valve lash appears. Mark
the flywheel with another
chalk line and the letters IC
(for intake closing) when the
intake valve lash
disappears.
Understanding Valve and Injector
Action in a Four-Stroke Cycle Diesel 6-3
If the engine uses unit
injectors, mark the
flywheel at the
approximate time the
injector plunger
begins to move
downward and
upward.
Understanding Valve and Injector
Action in a Four-Stroke Cycle Diesel 6-3
Record the engine
manufacturer and
model. Estimate the
approximate length of
each stroke (intake,
compression, power,
and exhaust) in
degrees using the bolt
hole spacing on the
flywheel.
Understanding Valve and Injector
Action in a Four-Stroke Cycle Diesel 6-3
Summarize your
findings by drawing a
polar valve diagram
like Figure 6-32.