Main Engines

Question 1

What gauges and alarms are on your main engine?

Answer 1

Onboard we have temperature gauges that read oil, coolant, charge air, thrust bearing, cylinder exhausts and gearbox.

We then have pressure gauges for oil, coolant, fuel, raw water, crankcase and stern tube flow.

All these are fitted with high and low alarms that will alarm and slow then main engines down. Then there are high high and low low alarms which will then shut an engine down to protect from further damage .

Question 2

What alarms will shut down the main engine?

Answer 2

• Low Low oil pressure
• Low fuel Pressure
• High High Coolant temperature
• Low low coolant pressure
• Overspeed
• High High exhaust gas temp
• High high thrust block temperature

Question 3

What monitoring devices and safety devices?

Answer 3

• Temperature sensors
• Pressure sensors
• Level sensors
• Overspeed sensor
• Fuel leakage
• Oil Mist
• Interlocks
• Position sensors
• Slow downs
• Shut downs
• Quick closing valves

Question 4

How does a speed sensor work and how do you know how fast your engine is going?

Answer 4

Magnetic Induction Sensors: These sensors use a magnetic pickup coil to detect changes in magnetic field strength caused by passing ferrous targets, such as teeth on a gear or a toothed wheel attached to the rotating component. As the target passes by the sensor, it induces a voltage signal in the coil, which is then processed to determine the speed of rotation.

To know how fast your engine is going, you rely on a tachometer, which is an instrument that displays the engine speed in revolutions per minute (RPM). The tachometer receives the speed signal from the speed sensor and converts it into a readable display.

Question 5

What could create a high exhaust temp reading?

Answer 5

• Incomplete combustion from a poor air to fuel ratio, possibly a leaking injector.
• Restricted exhaust from a build up of soot in the DPFs
• Overloading from bad weather, damaged propellor or a line around the propeller.
• Cooling issues from a leak, blockage, or trapped air pockets.
• Airflow restrictions from blocked filters or not enough air flowing into the engine room.
• Poor fuel quality due to water not being removed.

Question 6

How would you remove a cylinder head on the main engine?

Answer 6

• Check manufactures manual for a step by step procedure
• Organise Classification to come onboard for an inspection if possible
• Shutdown main engine
• Inform the bridge of the situation and request to stop all engines
• Inspect the issue
• Fault find it is an internal failure
• Lock the shaft using the shaft break
• Call all engineers for assistance
• Have a toolbox talk to create a plan
• Get classification spares and tools
• Request a permit and risk assessment
• Inform bridge
• Isolate battery switch and tag out
• Engage safety interlocks
• Isolate fuel, water and exhaust valves
• Take oil and coolant samples
• Drain coolant
• Remove fuel lines
• Remove wiring
• Remove air filter
• Remove inlet and exhaust manifold
• Remove rocker cover
• Remove tie down bolts
• Remove injectors
• Inspect cylinder head, exhaust ports and valve seating
• Inspect rockers and push rods
• Reinstall all of the above
• Check over work
• Open water and exhaust valves
• Remove interlocks
• Open indicator cocks and engage turning gear
• Turn on batteries and turn the engine 2 turns. Making sure everything id free to turn.
• Bleed off fuel until fuel is at each injector.
• Call bridge and inform you are ready to test
• Remove shaft break.
• Once started close the indicator cocks and stop after a minute
• Check oil and coolant levels, as well for any leaks
• If all is good sign off and record in the PMS and E.R Logbook
• Close permit.

Question 7

Draw an air start system and describe its components?

Answer 7

See onenote

Question 8

How does a cylinder start valve work?

Answer 8

It works by compressed air making its way to the automatic valve. Here it will wait while until the start signal is activated and the turning gear interlock is de-energised.

Air can now travel to the manifold via the non return valve and into the air start valve. At the same time air is sent to the distributor to which ever piston is on the firing stroke.

This is know as the pilot air and will act against a piston to compress a spring which also opens the valve head into the cylinder and allowing the main start air to enter.

Once the engine has achieved a certain speed the pilot air will shut off and stop combustion being able to travel back into the air system.

Question 9

What are the dangers of air start systems?

Answer 9

• It is high pressure, normally around 30 Bar
• Overpressurizing the cylinder can cause damage to the engine.
• If there is oil carry over there is a risk of explosion or a fire.
• High pressure air can generate a lot of heat also causing a fire.

Question 10

How would you assess the power of your main engine?

Answer 10

The method I have seen the most on yachts is bringing the manufacture onboard for a sea trial and they will plug a laptop in. We will communicate with the bridge going through different power ranges and they will collect all the data which can then be converted live into a readable outcome.

Bigger 2 stroke engines have the option of using a PV Diagram which by using an indicator drum and a plotting card can produce a graph showing compression pressure, peak pressure and engine power known as a draw card.

or a power card shows power output verse RPM, fuel consumption or torque.

Question 11

What type of maintenance do we do?

Answer 11

Onboard we aim for all maintenance to be planned maintenance which can be broken down into Calendar based, Running Hour based or condition based.

We always try to avoid unplanned maintenance.

Question 12

What are the normal clearances for intake and exhaust valves?

Answer 12

Intake is around 0.25mm and exhaust is around 0.30mm but varies from engines.

Question 13

Why are Intake and Exhaust valve clearances different?

Answer 13

It is to allow clearance when the exhaust valve expands from heat due to the combustion process.

Question 14

How would you set injector height clearances?

Answer 14

By using an Injector Height tool. They come in 3 sizes

Question 15

What types of common main engine faults are there?

Answer 15

• Fuel contamination from water, diesel bug or foreign objects blocking filters and reducing fuel pressure.
• Worn fuel injectors causing poor combustion and overheating
• Lub oil contamination from fuel, water and foreign objects causing sludge or a reduce in lubrication leading to engine wear
• Fowling in the sea chests and coolers from marine growth, causing a drop in raw water pressure and cooling effect
• Dead batteries or weak batteries or a faulty charging system
• Loose connections over time from the vessel vibrating causing sensor failures or incorrect readings.
• Blocked DPFs from operating at low rpms causing a build up of soot and rising exhaust temperatures and pressures

Question 16

Why is the Engine Room Log book so important?

Answer 16

• By keeping a record an engine room log can build a record of events, temperatures, pressures and levels.
• This can then be used for trends and for future voyage planning
• It is also evidence to classification, flag and port state that you are following regulations like performing test and drills. It can cover the engineer legally if an issue was to occur.
• It can be used to record breakdowns.

Question 17

On older 4 stroke main engine, how would you determine compression on cylinders with engine running?

Answer 17

By taking the peak pressure of each cylinder, as the engine isn’t common rail so each injector needs to be individually adjusted and balanced as they wear differently.

Question 18

How do you assess engine performance?

Answer 18

On 4 strokes it can be assessed by the common rail pressure, computer softwares, indicators on the fuel pump, peak pressures and performance logs.

2 strokes it can be assessed by draw cards and cam followers.

Question 19

How often would you check Main Engine Safety devices?

Answer 19

Onboard we check them before every major crossing and once a year on our PMS.

Question 20

What is overspeed trip and How would you test overspeed trip?

Answer 20

Overspeed trip will shut the engine down in the event of overspeed, protecting the engine in the event of failure of the governor or loss of load.

To test I would refer to the MTU Manual which would involve adjusting the set point to a much lower speed. Then turning the engine on and waiting for it to get to the new set point and shut the engine down.

Once the test is completed, return the overspeed trip to original set point.

Question 21

What would you do in the event of bottom end failure on one of your engines whilst underway?

Answer 21

• Organise Classification to come onboard for an inspection if possible
• Check manufactures manual for a step by step procedure
• Shutdown main engine
• Inform the bridge of the situation and request to stop all engines
• Inspect the issue
• Fault find it is an internal failure
• Lock the shaft using the shaft break
• Call all engineers for assistance
• Have a toolbox talk to create a plan
• Get classification spares and tools
• Request a permit and risk assessment
• Inform bridge
• Isolate battery switch and tag out
• Engage safety interlocks
• Isolate fuel, water and exhaust valves
• Take oil and coolant samples
• Drain oil and coolant
• Remove oil and fuel filters
• Remove fuel lines
• Remove wiring
• Remove air filter
• Remove inlet and exhaust manifold
• Remove rocker cover
• Remove tie down bolts
• Remove injectors
• Inspect cylinder head, exhaust ports and valve seating
• Inspect rockers and push rods
• Remove sump pan
• Remove bottom end bolts
• Remove pistons and inspect the cylinder linear
• Take linear measurements using a microammeter. Taking top, middle and bottom readings.
• Inspect piston skirts and gulden pin
• Inspect oil control ring, scrapper ring and compression ring
• Inspect ring channels for a build up of carbon
• Measure butt clearances on the rings
• Inspect piston crown
• Inspect bottom end bearing
• Inspect cam shaft
• Replace the bottom end bearing and other damaged parts
• Refer to manual for correct torque of the tie down bolts
• Reinstall all of the above
• Check over work
• Refill with new oil and coolant
• Bleed off air in jacket water
• Open water and exhaust valves
• Remove interlocks
• Open indicator cocks and engage turning gear
• Turn on batteries and turn the engine 2 turns. Making sure everything id free to turn.
• Bleed off fuel until fuel is at each injector.
• Call bridge and inform you are ready to test
• Remove shaft break.
• Once started close the indicator cocks and stop after a minute
• Check oil and coolant levels, as well for any leaks
• If all is good sign off and record in the PMS and E.R Logbook
• Close permit.

Question 22

Explain a thrust block failure scenario?

Answer 22

• Oil failure
• Bearing Failure
• Alignment increased wear
• Foreign objects scoring
• Water contamination

Question 23

What is the difference between a 2 stroke and a 4 stroke?

Answer 23

The operating cycle of the 2 are different. With a 2 stroke it will have a power stroke per every rotation where as a 4 stroke has a power stroke per every 2 rotations.

2 strokes tend to have an inlet port rather than an inlet valve while 4 strokes will have inlet and exhaust valves.

2 strokes have a greater power to weight ratio but a 4 stroke is a lot more fuel efficient and produce lower emissions.

Question 24

List some air start safety devices

Answer 24

• Bursting disk to stop combustion coming back into the system
• Turning gear interlock, stopping air being supplied while turning gear is engaged.
• Relief valve on the air receiver to counter overpressurizing
• Air receiver drain valve to remove any water in the system
• SOLAS require a minimum 6 starts per engine

Question 25

Draw a central ME LO System?

Answer 25

See onenote

Question 26

Exhaust temp is rising on engine, what could be the cause?

Answer 26

- Incomplete combustion from a poor air to fuel ratio, possibly a leaking injector. - Restricted exhaust from a build up of soot in the DPFs - Overloading from bad weather, damaged propellor or a line around the propeller. - Cooling issues from a leak, blockage, or trapped air pockets. - Airflow restrictions from blocked filters or not enough air flowing into the engine room. - Poor fuel quality due to water not being removed.

Question 27

What type of sensor is used for a exhaust temp sensors?

Answer 27

A thermocouple or a RTD (Resistance Thermal Detection)

Question 28

How would you test an oil pressure sensor?

Answer 28

Remove the sensor and place in a test rig, apply pressure with reference to the manufactures guidelines and compare to actual readings.

Question 29

How does fuel get into the sump?

Answer 29

- Leaking fuel injector - Incomplete combustion - Worn piston rings - Cylinder glazing from long periods of idling

Question 30

What is a thrust bearing, what does it do and do you have a full or half set of bearings?

Answer 30

A thrust bearing is to support axial loads and prevent axial movement or displacement of rotating components. Axial loads can result from various sources, such as the weight of propeller or hydrodynamic forces of the ocean. On board we have a full set of bearings in the thrust pads bearing design as this can adjust to various loads from different angles

Question 31

Draw a 2 stroke and 4 stroke diagram?

Answer 31

See onenote

Question 32

What senses the speed of an engine?

Answer 32

Magnetic Induction Sensors: These sensors use a magnetic pickup coil to detect changes in magnetic field strength caused by passing ferrous targets, such as teeth on a gear or a toothed wheel attached to the rotating component. As the target passes by the sensor, it induces a voltage signal in the coil, which is then processed to determine the speed of rotation. To know how fast your engine is going, you rely on a tachometer, which is an instrument that displays the engine speed in revolutions per minute (RPM). The tachometer receives the speed signal from the speed sensor and converts it into a readable display.

Question 33

Draw and explain a power card?

Answer 33

A power card is used for power output verse RPM, Fuel consumption or Torque.

Question 34

Draw and explain the aft of the main engine to the propellor?

Answer 34

See one note

Question 35

List the possible causes of a low power output?

Answer 35

- Late injection - Exhaust valves not seating correctly - Tappet clearance incorrect - Turbo is fowled - Dirty air filter - Dirty fuel filters - Worn piston rings - Excessive oil viscosity

Question 36

What materials are used in a engine?

Answer 36

- Cylinder block is made of high grade cast iron as it is able to handle the pressure and temperature - Cylinder heads in made with cast iron or aluminium - Piston is made from cast iron or an aluminium alloy to withstand combustion temperatures and pressures - Piston rings are made by fine grains of cast iron - Connecting rod is made with alloy steel for its high strength - Inlet valves are made with silicon chrome steel with 3% carbon while an exhaust valve is made with austenitic steel. - Crankshaft is made with high tensile steel or cast iron for its high tensile strength - Piston pin is made with hardened steel - Engine bearing is made of steel or bronze

Question 37

Why are edges of crankshafts scalloped?

Answer 37

By having a improved radius it reduces any additional stresses while increasing strength and durability. It can also improve oil film formation.

Question 38

Explain a big end bearing construction and inspection?

Answer 38

The big end bearing typically consists of a two-piece or three-piece shell, often made of a durable material such as aluminium alloy. The shell forms the bearing surface that directly contacts the crankshaft journal. The back of the bearing shell may be coated with a thin layer copper, lead, or other soft metals, to enhance conformability and embedability. When inspecting we are looking for scoring, scratching, discolouration, or signs of overheating on the bearing surface. We can also measure the inside diameter of the bearing shell using a micrometer to ensure it falls within the specified tolerances provided by the manufacturer's specifications

Question 39

What is honing and why does it occur?

Answer 39

Honing is to achieve a precise and smooth surface finish on cylindrical surfaces. Honing removes any surface irregularities, roughness, or imperfections left by previous machining operations such as boring, grinding, or milling.

Question 40

Can linear be repaired and how do we check liners?

Answer 40

Cylinder liners can be repaired in 3 different ways, reboring, sleeving or honing. When checking linear we start of with a visual inspection, looking for any signs of wear, damage or corrosion. Using a micrometer we take 6 measurements going TDC, middle and BDC. these are taken in both Fwd to Aft and Port to Starboard.

Question 41

How do you remove a cylinder linear?

Answer 41

To remove a cylinder linear we uses a hydraulic puller to extract from the engine block but first we must remove any sensors and the retaining clips/ bolts.

Question 42

Talk through a Cylinder head overhaul and Piston Liner inspection

Answer 42

- Organise Classification to come onboard for an inspection if possible - Check manufactures manual for a step by step procedure - Shutdown main engine - Lock the shaft using the shaft break - Call all engineers for assistance - Have a toolbox talk to create a plan - Get classification spares and tools - Request a permit and risk assessment - Inform bridge - Isolate battery switch and tag out - Engage safety interlocks - Isolate fuel, water and exhaust valves - Take oil and coolant samples - Drain oil and coolant - Remove oil and fuel filters - Remove fuel lines - Remove wiring - Remove air filter - Remove inlet and exhaust manifold - Remove rocker cover - Remove tie down bolts - Remove injectors - Inspect cylinder head, exhaust ports and valve seating - Inspect rockers and push rods - Remove sump pan - Remove bottom end bolts - Remove pistons and inspect the cylinder linear - Take linear measurements using a microammeter. Taking top, middle and bottom readings. - Inspect piston skirts and gulden pin - Inspect oil control ring, scrapper ring and compression ring - Inspect ring channels for a build up of carbon - Measure butt clearances on the rings - Inspect piston crown - Inspect bottom end bearing - Inspect cam shaft - Refer to manual for correct torque of the tie down bolts - Reinstall all of the above and replace what is needed - Check over work - Refill with new oil and coolant - Bleed off air in jacket water - Open water and exhaust valves - Remove interlocks - Open indicator cocks and engage turning gear - Turn on batteries and turn the engine 2 turns. Making sure everything id free to turn. - Bleed off fuel until fuel is at each injector. - Call bridge and inform you are ready to test - Remove shaft break. - Once started close the indicator cocks and stop after a minute - Check oil and coolant levels, as well for any leaks - If all is good sign off and record in the PMS and E.R Logbook - Close permit.

Question 43

The 2nd engineer can’t start main engine?

Answer 43

Check the basics, have we got battery or air, do we have fuel, is the emergency stop activated, any local alarms, local control, has the Engine checklist been followed, is the turning gear engaged, what maintenance has recently been completed

Question 44

The 2nd engine is questioning the ISM Checklist

Answer 44

The 2nd engineer may question it but it has been approved by management and classification. It is there for his and the vessels safety

Question 45

Peak pressure testing using indicator cock. What would cause significant deviation from the engine mean in a single cylinder?

Answer 45

- Poor fuel timing - Dirty fuel injector - Faulty valve train - Poor air/fuel ratio - Worn piston rings - Cylinder overheating from lack of coolant - Build up of carbon deposits in both the cylinder and exhaust

Question 46

How would you check injection timing on an engine with individual fuel pumps?

Answer 46

I would crack open the fuel line and slowly turn the engine until I got fuel. then I would move onto the next until all are bleed and inspected.

Question 47

With cooling water plate coolers, what are the common problems regarding maintenance?

Answer 47

Marine growth in between the plates blocks passages and reduces heat transfer efficiency and can lead to reduced cooling performance. The plates loose pressure over time due to debris so need to be regularly backflushed. Gaskets can fail which can lead to one fluid being lost to the other and causing a contamination.

Question 48

What happens if salt water gets into your lub oil supply?

Answer 48

If salt water was to enter the tub oil system it would increase the viscosity and reduce the lubricating properties. This would cause an increase in wear as well as that salts being abrasive against the metal surfaces. Salt water is also highly corrosive and would also attack the materials inside the engine. All this would then contribute to increasing operating temperatures.

Question 49

What type of checks would I carry out on the main engines to determine their performance and efficiency?

Answer 49

Went on to say that the MTU’s have a function built in that will display their loading along with their fuel consumption. He asked how else it could be determined so said about peak pressures and power cards, but I could not do that on this engine as it didn’t have indicator cocks fitted. He seemed happy enough with that.

Question 50

Talk through a major overhaul of a main engine?

Answer 50

- Organise Classification to come onboard for an inspection if possible - Check manufactures manual for a step by step procedure - Shutdown main engine - Lock the shaft using the shaft break - Have a toolbox talk to create a plan - Get classification spares and tools - Request a permit and risk assessment - Inform bridge - Isolate battery switch and tag out - Engage safety interlocks - Isolate fuel, water and exhaust valves - Take oil and coolant samples - Drain oil and coolant - Remove oil and fuel filters - Remove fuel lines - Remove wiring - Remove air filter - Remove inlet and exhaust manifold - Remove rocker cover - Remove tie down bolts - Remove injectors - Inspect cylinder head, exhaust ports and valve seating - Inspect rockers and push rods - Remove sump pan - Remove bottom end bolts - Remove pistons and inspect the cylinder linear - Take linear measurements using a microammeter. Taking top, middle and bottom readings. - Inspect piston skirts and gulden pin - Inspect oil control ring, scrapper ring and compression ring - Inspect ring channels for a build up of carbon - Measure butt clearances on the rings - Inspect piston crown - Inspect bottom end bearing - Inspect cam shaft - Replace the bottom end bearing bolts - Refer to manual for correct torque of the tie down bolts - Reinstall all of the above - Check over work - Refill with new oil and coolant - Bleed off air in jacket water - Open water and exhaust valves - Remove interlocks - Open indicator cocks and engage turning gear - Turn on batteries and turn the engine 2 turns. Making sure everything id free to turn. - Bleed off fuel until fuel is at each injector. - Call bridge and inform you are ready to test - Remove shaft break. - Once started close the indicator cocks and stop after a minute - Check oil and coolant levels, as well for any leaks - If all is good sign off and record in the PMS and E.R Logbook - Close permit.

Question 51

How to adjust fuel timing?

Answer 51

Adjust the height of the HP piston pump

Question 52

Cylinder head has been removed and is on the work bench, what are you looking for?

Answer 52

Start with a visual inspection, looking for any signs of damage, wear, overheating. Look to see that all coolant passages and oil galleries are clear. look around the combustion chambers, valve housing and bolt holes for any fractures and cracks. Check the valves, looking at the seating, the springs, tolerances, valve, face, valve stem, valve guides. Inspect the combustion chambers, making sure there isn't a big build up of carbon deposits. Ensure the cylinder head is smooth with no indentations

Question 53

Sources of wear metals and different types in a main engine?

Answer 53

Cast iron = Pistons or Piston rings Silicon = Valves Steel = Piston pin Bronze/ Lead = Bearings

Question 54

When removing the gudgeon pin, what would you look for?

Answer 54

I would be looking for any signs of wear, scoring, overheating, scratchings, cracks, fractures, bends, twists. I would measure the diameter of the pin with a micrometer to see if there has been any uneven wear. Check the oil galleries for lubrication

Question 55

Turbo chargers, define and describe? What is the oil supply why? Housing arrangement, jacket cooling? Problems with turbos, how is your oil temp regulated?

Answer 55

A turbocharger increases engine performance by forcing more air into the combustion chamber. Allowing for more fuel to be added and increasing the output. A turbocharger consists of two main components: a turbine and a compressor. The turbine is driven by the engine's exhaust gases, while the compressor is connected to the engine's intake system. Oil is supplied from the main engine oil to the turbochargers bearings and shaft to allow continuous spinning. Constructed with cast iron to withstand high temperatures of the exhaust. Jacket cooling may pass off the main engine and around the turbo housing to remove some heat and reduce thermal stresses. Common problems with turbochargers include: - Bearing wear and failure due to inadequate lubrication or contamination. - Turbine or compressor wheel damage from foreign object ingestion or overspeeding. - Seal leaks or failures, leading to oil or exhaust gas leaks. - Carbon buildup or fouling on turbine or compressor blades, affecting performance. Oil temp is regulated by the oil cooler which uses heat transfer to remove the heat from the oil and into the cooling medium.

Question 56

Describe an injection system, describe a governor and how does the fuel rack governor distribute the fuel?

Answer 56

An injection system in a diesel engine is responsible for delivering precise amounts of fuel into the combustion chambers at the correct time and under appropriate conditions to ensure efficient combustion and engine performance. A governor is a device used to regulate engine speed by controlling the fuel delivery rate to the engine. The governor senses changes in engine speed and adjusts the fuel delivery accordingly to maintain the desired speed set by the operator or to respond to changes in load. A fuel rack governor is a movable metal bar or rack connected to the fuel pump's internal mechanism. The position of the fuel rack determines the amount of fuel delivered to the injectors and thus controls the engine's power output and speed.

Question 57

Describe an engine from the top with all the parts down to the sump?

Answer 57

Cylinder block Crankcase Cylinder liners Valves (intake and exhaust) Valve springs Camshafts Rocker arms Valve cover Pistons Piston rings (compression rings and oil control rings) Connecting rods Piston pins Main journals Connecting rod journals Engine Timing Components: Timing gears Fuel injection pump Fuel injectors Fuel lines Fuel rail (in common rail systems) Air filter Turbocharger Intercooler Intake manifold Exhaust manifold Oil pump Oil filter Oil passages and galleries Starter motor Battery

Question 58

What is the flywheel for?

Answer 58

The flywheel helps to smooth out variations in engine speed and torque, providing a more consistent and even power delivery to the drivetrain. It stores rotational energy generated by the engine's crankshaft during the power stroke. The flywheel often serves as a starting aid by providing rotational inertia to help overcome the initial resistance of the engine when starting.

Question 59

Talk me through the removal of a main bearing with a hydraulic nut

Answer 59

- Engine stripped down to this point - Refer to manual for pressures - Correct tools - Clean the thread and install base and threaded nut, ensuring alignment - Attach the pump and check the system over - Slowly pressurize and monitor up to the required pressure, you will see the thread stretch, now loosen the nut - Depressurize the system and remove nut - Remove top cap and remove the top side of the bearing.

Question 60

Talk through checking an injector on a test rig.

Answer 60

- PPE - Clean work area - Tools / Fluids - Visual inspection - Set up in rig with fuel lines and control lines - Referring to operating manual - Prime and bleed out air - Configure the test rig to manufactures spec - Pressurize system and perform leak test - Complete a static flow test, activate the injector and measure the amount of fuel it dispenses over a set period - Spray pattern test, ensuring correct atomizing - Simulate under different loads/ speeds - Check the opening and closing times by measuring its response time - Compare to manufactures guidelines - Identify issues and repair - Clean and reinstall - Document findings

Question 61

How would you set up injector timing?

Answer 61

- Turn the engine so the cylinder is at TDC - Install a dial gauge in the specified location on the injection pump and set gauge to zero - Reverse the engine backwards by a specified amount in the manual - Rotate the engine forwards until the specified timing value is reached on the dial gauge. Given in mm and represents the lift of the injector plunger - If incorrect reading the loosen the injector pump mounting bolts and rotate the pump slightly to advance or retard the dial gauge - Check the system again - All good the torque everything back to normal.