6

Diesel Fuel Shut off Valve Functions-Issues

This fuel shutoff valve is a part of the injection pump that functions as the shutoff of fuel and engine.  It is operated by a current from the battery through the ignition switch.

When the ignition switch is on and current goes to this shutter it opens and fuel will flow to the injection pump that supplies the nozzles spraying fuel to the combustion chambers. When the ignition switch is off this valve will close and no fuel will flow to the injection pump.

How Diesel Fuel Shut off Valve Functions-Issues-shut off valveHow Diesel Fuel Shut off Valve Functions-Issues-shut off valve

How do you know this?

I would like to share with you our experience in the Toyota L engine. We have just overhauled it, the radiator was overhauled too, and the injection pump calibrated.  Everything should have been fine as expected.  The engine was cranked and it started smoothly, the engine noise is just right, the thick white smoke is gone and is about to be on a road test.

But as the engine is warmed up it suddenly stalled, no matter how you crank it in order to start it didn’t. Because it’s newly overhauled maybe the fuel has not yet fully saturated the injection pump and air maybe inside. The remedy is to loosen the nozzles so that air may be blown out.

This process if the air had been totally out from the injection pump fuel should follow to come out of the nozzles. If there are no bubbles coming out it’s time to tighten it.  Loosening the nozzles to test if there is fuel in it should be done one after the other.

However, this time there was no air coming out and there was no fuel too.  So how would the engine start if there is no fuel supplied by the nozzles? It will not. It’s good the fuel hose is transparent and obviously, the fuel is still sufficiently available from the tank.

The next step is to check if there is a current going to the fuel shutoff valve.  So we checked it and there was no current.  Upon examination, it was the wiring connected to the shutoff valve that has been cut off inside, however, it was not obvious until we stretched it out and it was only connected temporarily through the insulation of the wiring.

When the connection was restored the engine was cranked and it started until it was tested on the road and until this time of writing the engine did not stall.

0

Toyota L Engine-Weak Power Resolved

Too weak, and overheating after it has been overhauled. It ‘s unbelievable. When your engine is pretty working when it was not yet overhauled you will wonder why and you may blame the mechanic for such condition.  It should work efficiently because it was newly overhauled.

This newly overhauled Toyota L Engine displayed a weak power when it was road tested. Whatever you do with the timing either you advance it or retard it, it does not make any change in the power. The engine nearly cannot pull its body on an elevated road.

The technician believes everything is in its proper place and the issue has nothing to do with the overhauling. He rather recommended that the injection pump is calibrated.


What is Calibration?

Calibration includes replacement of O-rings, oil seals, cleaning and testing with a machine if the injection pump functions accurately or not.

Toyota L Engine-Weak Power Resolved-Injection Pump

This is an additional expense for it is not easy when you don’t have the budget. The cost is two thousand seven hundred pesos (P2,700.00).

The injection pump was brought to the Calibration Center, disassembled and cleaned.

Toyota L Engine-Weak Power Resolved-Injection Pump Parts

 

 

And then assembled and put to the test machine.  Now, we don’t know what would have been the defect of the injection pump since it was disassembled without the test first.  If it would have been tested before it was disassembled maybe we have known if it is clogged or any of the adjusting screws have been meddled in by a mechanic in the previous years.

Toyota L Engine-Weak Power Resolved-Calibrated Injection Pump

The purpose of the calibration now is all specks of dirt which have been sucked from the fuel are to be removed and to return the function of all parts in the normal way.

Calibration

All tests have been done and the injection pump was hopefully in good condition. Back to the engine and the pump was attached.  After everything had been placed, the engine was started.

Noticeably, the engine is now quieter, less smoke and the engine’s power was restored.  It was a grueling task but it’s worthy to have been done. No issue on the overhauling but it’s outside the engine, it’s the fuel injection pump.

 

 

 

 

 

0

Toyota L Engine Overheating Resolved

It was a shocking experience about overheating engine when it was not really overheating before it was overhauled. It was a sudden additional situation which we addressed after trying to solve the issue of weak power. The story is this:

We overhauled the engine because it came to a stage that it emits thick white smoke and it does not have the power. Other than that is because oil and water are mixing in the radiator. But in addressing that issue another problem came up when we test drive, it was overheating reaching 180 degrees Fahrenheit (°F).  That is already near to the boiling point of water which is 212.  That 180 degrees Fahrenheit (°F) should be the temperature when fully loaded and you climb uphills and the temperature of the day is really hot.

When the temperature reaches that point all moving parts inside the engine starting from the piston will stop to move because they are stuck due to the heat.  Meaning, the oil and the water or coolant are no longer capable of providing the proper lubrication for the engine to work smoothly.


The Radiator Overhaul

Toyota L Engine Overheating Resolved-Radiator

In our, analysis there would be no other source of the overheating problem other than the cooling system.  The oil is working properly as seen in the oil gauge so it must be the radiator.

I had to bring this to the shop for overhauling. 

Toyota L Engine Overheating Resolved-Radiator shop

The usual overhauling of a radiator is detaching the top cover to clean the core tubes by rubbing the core tubes with a thin deep stick. However, if there is clogging that cannot be pricked they will just leave that clogged.

So what we did is to remove both the top and bottom covers. Here is the picture below.

So we found out that there were several core tubes clogged. Aside from that, there was a perforation where the water leaks. We did the cleaning and fixing. But as you see after it has been assembled there are perforations on some of the core tubes so it has to be soldered.

The overhauling has been over the usual fixing that is only the top cover.  This time both the top and the bottom covers were removed and the clogged core tubes were cleaned thoroughly which is much better than the prior condition.

 
We have fixed it by maybe four times testing it with water if there no leaks.  After proving that it’s already free from any defects I took it to the vehicle and attached it to its proper place.

We test drive it and the issue of overheating has already been solved.  Thanks for a job well done by the repairman for both the engine and the radiator.

See you again on the next posts.  If you have any questions, suggestions or opinions that you think it can be incorporated here just use the comment box and we will consider all of them.  We will get back to you as soon as we read your messages.

Remember, the engine feels your love.

 

0

Toyota L Weak and Overheating Engine-Newly Overhauled

We have overhauled a Toyota L engine just this week and came to a puzzling issue on why it lost its power and is overheating.

Prior to overhauling the engine had overheated due to the radiator hose bursting.  It was immediately addressed during that day and everything was fixed and we used the car onto the occasion we went through.

However, after going back home the owner noticed that the coolant was being mixed with oil. The oil cooler gasket was replaced and to make sure everything was fine the cylinder head gasket was also replaced. Those steps did not solve the issue, the more the car emits thick white smoke.

This time the owner decided to let the engine overhauled.

The car was brought to the mechanic and the engine disassembled. Noticeably, the four cylinders were having the same uneven and marked sides.

The mechanic recommended that the cylinders be replaced with a standard size or oversize it with a 0.50 mm.

The owner happened to decide on the 0.50 sleeves be oversized. He brought the block to the Machine Shop for oversizing and went ahead and bought all the 0.50 piston, piston rings.

Weak and Overheating Engine-Newly Overhauled-0.50 size piston

After one day he went back to the Machine Shop because he was called to decide on what will they do. On the image below they have shown the owner that the sleeve has a crack around near the top and they don’t recommend it for oversizing rather it should be replaced with a standard.

Weak and Overheating Engine-Newly Overhauled-oversize cylinder

Since he bought all the oversize piston and piston rings through an order, it cannot be returned and the only remedy is to buy a standard sleeve then oversize it. It was an unexpected additional expense, however, the parts have to be utilized and no other choice.

 

The four standard sleeves were rebored and honed

After these sleeves were rebored and honed the engine is ready to be assembled. With new overhauling gasket, it includes the cylinder head gasket, the oil cooler gasket, new crankshaft oil seal, new camshaft oil seal, new cylinder head cover gasket, new crankcase cover gasket, and others. New sets of 0.50 sleeves, 0.50 piston, and piston rings.

The engine assembled with a new look, freshly cleaned inside and outside.

The engine attached to the body and the new engine life is first started successfully.  The sound is fine enough and you are contented with what you have done. The noise is just fine and it needs breaking-in for hours before it is normally used again for services anywhere.

Road Testing

After one day we tested it on the road and upon climbing up the hill there was no power even to the first gear.  It could just move on a plane lane and when you forced it to an elevated road it overheats and stalls.

The coolants are obviously circulating both oil and water that clearly puts the impression that the coolant pump is working fine.

This is the first time I experienced a newly overhauled engine with no power.  It’s a puzzle I and the mechanic have to discover.

I wish my readers could help in the solution of the issue at hand.  Please kindly post your comments down below the comment box.

What do you think is the reason behind why this engine has no power instead of a renewed strength and life? What steps and solutions should be done to restore this engine to its power?

 

 

 

4

Cylinder Liner-Cylinder Sleeve Issues

The image below is called a cylinder liner or a cylinder sleeve.  This auto part is inserted into the engine block. In other engines, there are no cylinder liner or cylinder sleeve, they only have cylinders directly part of the block.

The cylinder liner is where the piston goes up and down for intake and exhaust system. This is directly lubricated by the engine oil.  In order for the oil not to be mixed with the fuel, a piston ring is needed to seal the space between the piston and cylinder liner or cylinder sleeve for better compression and avoid overheating in the engine.

When the piston ring or the cylinder liner is perforated oil will be pushed up into the fuel chamber and it will be mixed making a bluish smoke emitted by the engine.

In many cases, if signs are obvious there is a need for the piston rings to be replaced for proper engine oil sealing.

Cylinder Liner-Cylinder Sleeve Issues-cylinder sleeve

However, if the cylinder liner has already scratches which the piston rings cannot seal, the cylinder liner has to be replaced, it can be oversized from the standard measurement to 0.25mm or to 0.50mm.

If cylinder or cylinder liner is necessary for oversizing piston and piston rings should also be replaced with 0.25mm to 0.50mm.

However, others opt not to replace the piston but only the piston rings for practicality reason. If your car is not for racing they don’t advice you to replace the piston but only the piston rings.

Oversizing the cylinder liner, piston and piston rings has started with the myth of having a larger size other than the normal one is stronger and faster you can take advantage of.

So make a choice if you are the owner of the car. If you are in a race and you believe on the myth of oversized cylinder liner then you do.  Because this will surely be the advice of the persons who work in the Machine Shops.

However, if you use your car for family services and necessities you may just have the piston rings to be replaced with an oversized one.

 

Cylinder Liner-Cylinder Sleeve-Inserted into the engine block

The Issue on this Cylinder Sleeve

As you can see from the above image of the cylinder which is about to be oversized, there is a lining around near to the top.  You don’t see a crack but a color pencil like. The serviceman decided not to continue oversizing it until the owner decides for it.

The oversizing is to 0.50mm because of deep scratches made by an unknown cause. For sure even you replace the piston ring it cannot seal the engine oil to go up and be mixed with the fuel.

The mark is far above where the piston ring can reach. It’s a part of the combustion chamber.

Find related issues here on bluish smoke.

Thank you for reading.  I hope it helped you.  Please drop a comment below and I’ll get back to you as soon as I read it.

 

 

 

2

Circuit Relay Related Issues

Have you had experiences that your car stalled during your journey? It’s difficult to ascertain what could be the cause. This circuit relay issues can be new to you and you need to know about it so you will consider and include it in your diagnoses if ever your car frequently stalls.

You know your battery is in good condition.

You know you have enough fuel.

You know the fuel filter is doing its function effectively.

You might think the injection pump of your car needs to be calibrated.

But wait before you do the laborious and expensive repairs and fixtures, there is one thing you should first check and this is related to electrical issues.

I would like to prove to you what I am saying.  Here goes the story.

For thrice my car has been stalling in the midst and at the crossroads and it was a shameful situation. Isn’t it? I was causing the traffic.  

Because the engine can be cranked but cannot be started we have to push it and after doing so the engine finds its way to start over again.  

There was a time that along the way I have to call for a mechanic to see what was faulty. But as it was a joke the engine started and we got home but after several days it sometimes starts and sometimes it doesn’t.

At this point in time, I called my friend mechanic to once and for all diagnose the issue causing the inconveniences along the way.

We started the engine and as he inspects every angle he happened to bump on the electrical circuit and the engine stopped.

Circuit relay issues-circuit relayWhy Engine Stalls When Hot or During Long Trips-worn out contact points-circuit relay

Now we have discovered that the sockets are too loose and when the car is running and the current line is detached it stalls because no current to burn the fuel.

The following images below are the ones installed in my car.  Maybe your car is newer and you have a more advanced circuit relay.

I have to buy a new one and changed this old circuit relay.

Circuit relay issues-circuit relay

Circuit relay issues-circuit relay

 

What does this circuit relay do?

This circuit relay controls the electrical flow from the battery to the fuel control valve.  If electrical fails due to a defective circuit relay the fuel control valve doesn’t do anything and the fuel will not flow to the fuel injection pump.

Circuit Relay Issues- Fuel Control Valve

Fuel Control Valve

Although there are some fuel passages that supply the injection pump since there is no current nothing can ignite the fuel in the combustion chamber.

For sure your engine is being cranked but it will not start.

 

2

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2

Oblong Rear Tire Can Seriously Deceive You

I have been deceived for almost two months until I have discovered that the problem does not lie on the engine nor on the transmission but something else.  Watch the video before you continue to read what I would like to share with you this time.

The first time I felt as if the break was not evenly fitted or something wrong in the transmission.  I paid time to check the brakes but they were in proper positions.

Not sure of what is the problem all about we continually used the vehicle.  But as time went on the more eminent the disturbing sound and shaking especially when loaded.

I had to look for a mechanic and since there’s evident sound coming from the differential I decided that it be fixed.  However, we have already fixed the problem in the differential but that shaking remained.

I consulted another technician and we even tested and he said, maybe it’s the clutch.  I inquired if how much would be the expenses if ever his suspect is right.  He answered, maybe you will spend a maximum of five thousand pesos.

Because I don’t have that amount I did not let it be disassembled. A week passed and I was still using the vehicle for church work not so far so it would not incur much difficulty if ever it stalls.

This time I went to our friend and fellow church member and a mechanic.  We rode the vehicle and drove along the highway. After around three kilometers we stopped on a safe place along the highway and jacked the rear tire one after the other.

As per instruction of the mechanic I started the engine and let the tire rotate.  The right rear tire was not rotating smoothly but the left rear tire was still good.

It’s not a problem of the wheel but the tire that is already oblong.  As you have viewed on the video above the rotation is not normal.

Because the mechanic said that the tire should be replaced I have to do so.  I had to look for tire center and it caused me eighteen kilometers to have it replaced. Not only one tire but both because the problem might be repeated.

It cost me more than seven thousand pesos but it solved the problem.  We went home with joy and satisfaction that our expenditures went to the right thing.

It’s really deceiving because in my own impression the tires are still new because the grids are still deep and didn’t show a serious and impending ware and tear problems.

Now I know that you cannot judge a book by its cover.  Although the tire appears to be durable the six years speak that it’s time to be replaced.

Now it’s safer ever again and you can be calm as you drive anywhere. Thanks to the mechanic.

 

 

6

Reasons Why You Need an Engine Overhaul

Overhauling an engine is an expensive process which to any car owner is undesirable.  

This is what you expect when you bring your engine into a shop for overhauling. Calculated in pesos, the Philippine currency.

P5,000   Service fee for the mechanic;

P12,000 Machine shop repair and service fee, this includes

  • cylinder head resurface
  • cylinder honing
  • cylinder sleeving
  • main journal regrind
  • connecting rod journal regrind
  • connecting rod fitting/conversion
  • connecting rod bushing hydro bore honing
  • main housing and caps line boring
  • valve refacing
  • valve guide replace
  • valve seat ring insert
  • turbo blast degreasing
  • and oil seal build up

P13,500 Cost of parts to be bought includes:

  • a set of overhauling gasket
  • a set of piston rings
  • a set of connecting rod standard bearings
  • standard main bearing
  • set of liners and a crankshaft

P27,000 Total expenses.  This is not a joke.

Is there anyone of you there can offer a cheaper service?

 

Reasons for a Need of an Engine Overhaul-Toyota L Engine overhaul




Reasons why a Need for an Engine Overhaul

1.  Bluish white Smoke-this is sometimes called blue-gray-smoke.  It is a symptom that there is oil leakage and is being mixed in the combustion chamber.  Oil maybe passing through the valve, or through the head gasket.  It may also be through the worn piston rings or perforated sleeves.  The worst thing is the block has a crack but this is very rare. If this bluish white smoke appears it is necessary to have an overhaul.

What is to be done?
If you are sure of what the causes are especially if they are obvious it would be easier for you.  But if you are not sure you need the following to be done: 

  • valve replacement
  • valve seat replacement
  • valve guide replacement
  • piston ring replacement
  • gasket replacement, and
  • cylinder head resurface.

Hopefully, after administering all those parts replacements the issue should have been resolved.  If the issue remains you have the worst thing and that is an engine block replacement due to a crack.

It is, therefore, best if you bring your engine in a shop for overhaul let the engine block be inspected first to ensure you will not repeat the same task after everything has been done.

Possible Causes that Contributes to the Damages of Parts Mentioned Above

1. Oil Deficit-an often oil deficit in a long trip is definitely a cause to the damage of engine parts like block gasket, valves, valve seats, not so usual with valve guide or valve stem.
Lack of oil will cause engine overheating.

2.  Irregular or a Late Oil Change-this has something to do with oil viscosity.  If oil is already viscous before you change it adds to the high temperature of the engine.

3.  Lack of Coolant-this is why water as coolant is very important on every journey. Be sure to inspect your radiator if it has sufficient water. Lack of water causes engine overheating.

All of these oil deficit, irregular or a late oil change, and lack of coolant are causes of engine overheating that can melt the block gasket even the valves and valve seats.  It could even result in sleeve perforations and the worst thing the block cracking.

Why not attend to the symptoms and address it immediately than to wait and incur a four hundred times of expenses and much time spent.

 

 

6

Diesel Injector Nozzle Calibration

Diesel injector nozzle calibration is necessary when your car is an old model which had been used for decades because parts have passed through heat over time and may have weakened, or have perforations.

Diesel injector nozzle calibration-injector

 

This service is also needed in modern cars which are digitally equipped but may have encountered fault in a program that feeds the wrong message to parts that perform the measurement of the right amount of fuel for the engine.


Why calibrate injectors?
A fuel injector is an assembly or group of parts assembled and otherwise called a nozzle. Sometimes the whole thing is called the nozzle and the end part of the injector where the fuel comes out is also called a nozzle.

The function of the injector is to control the flow of fuel through the injection nozzle to the combustion chamber.

On the passage of time, one of the parts may have weakened or had perforations and for that reason, the right amount of fuel to be supplied to each cylinder is no longer normal causing more emission of smoke undesirably affecting anyone around.

The primary reason why injectors are calibrated is to bring it back to the original pressure that supplies the right amount of fuel to the cylinder for efficient performance.


How is Calibration Done?
This should be done by a professional technician unless you have the devices to use and you know the proper pressure.

The reason is that calibration is not just cleaning the injectors but it is to check the pressure and if it is not in the desired one it should be put back to the original pressures.

Why has the pressure possibly changed?  There are two reasons that contribute to this state, the nozzle spring and the injection nozzle.

Diesel injector nozzle calibration-nozzle spring

Diesel Injector Nozzle Calibration-Nozzle

As I have said there are parts that may in due time weakens or perforated because of heat.

If the nozzle spring has weakened the pressure has loosened and more fuel is sprayed to the cylinder.  The remedy is to change the shims to a thicker to add pressure to the spring.

If there are perforations on the nozzle or the nozzle needle there is no other remedy than to replace the injector. You cannot control the flow of the fuel by adding shims to add pressure to the spring.

 


Disassembled Diesel Injector

Diesel injector nozzle calibration-disassembled injectorDiesel injector nozzle calibration-disassembled injectorDiesel injector nozzle calibration-disassembled injectorDiesel injector nozzle calibration-nozzle cleaning


Possible Symptoms when Diesel Injector needs calibration

Black smoke-this is a sign that fuel is over to the limit needed by the engine for combustion.  Not all fuel is being burned and so it is wasted and emitted outside. If smoke is white oil is passing somewhere the cylinder or cylinder head gasket and is mixed with the fuel in the combustion chamber.

 

The Nozzle Tested on a Pressure Guage of 125 Pounds Per Square Inch (PSI)


Rough Engine Idle

Assuming that you have fixed all the proper idle speed, no vacuum leaks, no damaged or incorrect spark plug gaps (for the four-stroke engines), you have calibrated your fuel injection pump but the idle is still rough it’s time for you to have your fuel injector calibrated.