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.