4841 Battery testing

SAFETY: Safety glasses should be warn at all times and a nearby water supply should be available 


1. Visual Check
Check the battery case for cracks,swelling and leaks (battery need replacing if any of this 3 sign is showing).
Check electrolyte level in all cells that they are at the correct level  add distilled water if needed (using tap water will shorten lifespan of battery and DO NOT over fill).
Check battery terminals for corrosion and residue, clean if needed (wire brush)


2.O.C.V (Open Circuit Voltage) Test
Tools needed: Voltmeter
Then to remove surface charge with the car off turn the light on for 1 min (if surface charge is not remove  results will be incorrect making a weak battery appear good and good battery appear bad.
Black lead of voltmeter to negative(-) of battery and Red lead of voltmeter to positive(+)
make sure everything is turn off....int/boot lights, ignition key out,  door close.
Compare results with table below

Readings:

12.6 V – 12.7 V = 100% of Charge

12.45 V – 12.5 V = 75% of Charge

12.3 V – 12.4 V = 50 % of Charge

12.15 V – 12.2 V = 25 % of Charge

3.Hydrometer Test
Tools needed: Hydrometer
Unscrew cell cap. Depress the pump fully and insert the hose at the end of the tube into the cell hole, release pump and electrolyte should start flowing into the tube which then should floats the weight. Look at the tube at eye level and this should give you a reading.

1.240 – 1.260 = 100% Charged

1.210 – 1.240 = 75% Charged

1.180 – 1.210 = 50 % Charged
1.150 – 1.180 = 25 % Charged

4.High rate discharge (Load) test

Tools needed: Load tester
Connect load tester positive lead to positive terminal negative lead to negative terminal. Find the cold cranking amp (CCA) for your battery and half it (half 550CCA = 275A). Set the load tester to 275A and leave it for 15-20seconds during the test the battery voltage should not drop below 9.6 volts.
OR
Tools needed: Voltmeter
Unplug EFI fuse, connect volt meter to battery and crank the engine voltage display should not drop below 9volts.

5.Amp Draw Test
Tools needed: Ammeter
With the car off (key out, no lights on, doors close, boot close....), disconnect the battery negative (you might want to hook up a jumper wire first so you dont loose your memory then once ammeter is wired up you can unhook the jumper wire) and hook up the ammeter in series the result should  around 30-50 mA

6.Digital Battery Test

This is what battery dealers use now a days.  make sure the voltage of the battery is not below 7 volts because the tester will be powered by the Battery being tested. Connect tester to battery terminals positive to positive and negative to negative. When connected the tester should display the voltage of the battery. Using up down arrow buttons choose the CCA of your battery eg 550 CCA, then press test button. The digital battery tester might show CH which means battery need charging to continue the test or give you a result of PASS (no faults found and battery is in good order) or FAIL ( Something is wrong with the battery).

4841 Alternator

An alternator is basically a generator but instead of running on fuel an alternator in a car converts mechanical energy to electrical energy in the form of alternating current (AC).  


On car test 
Voltage (when car is off)=12.6v
Current (No load)=17A
Voltage test (when car is running)=14.6v
Load test (heater on light on)= 45A




Off car test

Rotor winding to ground test
Set the ohmmeter on 2K.  Place the black lead on the centre of the rotor shaft . Place the red lead on the slip-ring.There should be no circuit between the rotor shaft and the slip ring. 
The meter should read infinity O.L

Rotor winding continuity test

Set the Ohmmeter on 200Ω, test for internal meter resistance by touching the two leads together.Place one end of each lead on the slip rings . Result minus  internal meter resistance.The result should be 2-6Ω

Testing stator winding resistance

et Ohmmeter on 200Ω, Remember that the internal resistance of the meter must be taken away from the actual reading.  Select the common terminal (the one with the most wires attached) of the stator winding terminals A to D.  Connect the black lead to the common point.  Connect the red lead to the other terminal one after the other and record their resistance they should all be approximately the same from 0.0Ω - .2Ω

Testing stator winding earth leakage test
Set the meter on 2K.  Place the common lead on the body of Alternator as indicated.

Place the red lead on the common stator winding terminal (the terminal with more wires connected to it). There should be no circuit between the stator winding and ground.  The meter should read infinity.

Testing rectifier positive diodes

Set the meter on ‘Diode Test’  mode. Put the common lead on B terminal. 

Then touch the positive lead on each of the P terminals and record the readings.The voltage

should be 0.6-0.7 V.

Testing the rectifier negative diodes

Testing voltage regulator

the regulator i tested show a voltage of 12v which is a bad regulator. Good regulator should show 14v

Other ways of testing a alternator

Using a test light tough all the terminals and do ground test. places where should be connected should light places that shouldn't be connected the light shouldn't come on.

4841 AC TO DC

BLOCH

AC

Diode Bridge

LED

Capacitor

5v Regulator

LED
Capacitor

DC 5v out put

CIRCUIT 

LOCHMASTER 

PARTS LIST 

4x Diode 1N4007 1A 1000v

1x 560R resistor

1x 390R resistor

1x Red led 3mm 30mA 2.2v

1x Green led 3mm 30mA 2.2V 

2x Capacitor 35uF 

1x 5v Ragulator 1A 7805 

HOW IT WORKS 

AC goes through bridge rectifire(diode) comes out DC goes through filter (capacitor) then indicator(red led) then go through 5V ragulator  which the turns the 16V DC to 5V DC  then goes through another filter (capacitor) then another indicator ( green led)  then DC out put.

CIRCUIT BOARD TESTING

Red lead of multimeter to yellow wire on the board 

 Red lead of multimeter to red wire on board

Petrol injectors

Basic injector test 

Using a screwdriver place it on the metal body of the injector and you should hear a metal click every time the injector open

Multimeter lead to terminals of injector this should give us a reading of around ...ohms ( check service manual for specification ), if you are not getting a reading  or it is not within specification the injector is defective

To check for ground/short set the multimeter to ohms then  + to body, - to body this test dis play .OL or 1. on the multimeter there should be no connection

Further testing

Now to check if the injector is spraying properly.

This machine will put it through flow testing and by visual you should be able to tell if the injectors are leaking or block. the spray pattern should be a clean cone shape not a drip.The level of fluid in each cylinder should also be the equal.

4841 Diode and LED

What is a diode

Diodes is a electrical component that is use in circuits to only allow electric currents to go one way. 

P= P-type (hole)             A= Anode +
N= N-type (electrons)    K= Cathode -

How to pick a diode.
-Choose the correct amp needed
-Choose the correct voltage needed


Diodes are sold in amps and voltage
eg      1A                       3A
     1N4001   100v    1N5408
     1N4004   400v    1N........
     1N4007  1000v   1N.......


above are example of diode.1N4001 can handle up to 1A and 100v. 1N5408 can handle 3A and 100v. 1n4007 can handle 1A and 1000v and so on....




LED (Light Emitting Diode)

LED's are diodes that light up.They were first use as indicators but are now use in many devices eg TV, Cars, Cell Phones..... They come in many colours (even once that can change colours) , shapes and different sizes  8 mm, 5 mm and 3 mm.




Work out resistor to use with it
R=resistance
Vs= Voltage supply
Vl = LED Voltage (2V for all but 4V for white and blue LED)
I= LED Current needed (20mA change to A =0.02A for formula)


Fomula
R=(Vs-Vl)/I


eg R=(12V-2V)/0.02
      R=500ohm

4842 Engine Oil

Engine oil is a lubricant that is use in engines for the main reason of lubricating moving parts in a engine to stop  wear to happen but has lots of benefits include improve sealing, cleaning the engine, stop corrosion and helps cool moving parts by carrying heat away.


Full Synthetic engine oil is a man made (chemist) engine oil, these engine oils are the most accurately match  and constant performance oil. These oil are perfect for constant high stress engine.


Semi Synthetic is the next best, these are made by some nature oil and man made oil.Semi Synthetic are  good for average road users and are a cheaper option.


Multi Grades  


Multi grades oil are always use these days, single grade oils are not used any more because they get too thin when hot in modern cars.These are great for protection at start up and at high temperature.On engine oil bottles two  viscosity numbers are presented eg. 10w-40.The 'W' stands for winter which is a guide to tell the thickness of the oil when its at cold temperature (cold start) the lower the number the faster the oil will cover the engine at start up. The 40 is the thickness of the oil at boiling (100 degrease) temperature.


How to chose the correct oil grade


Choosing the correct oil is critical, most people think a higher grade will lubricate better but if it doesn't flow well and through small bearings then it will not lubricate all the parts in the engine properly and some parts may ark weld and cease that said a thinner oil will give good mileage because of less resistance and better flow  but if its too thin then the oil will not lubricate properly which cause the engine to wear. A perfect grade will be to look in the service manual and start from there go up and down  grades depends on temperature of the place you stay and drivers use (travel/short distance drive)


When to change my engine oil


Usually the service manual say 10,000 km in reality it all depend on how the car is being use and the condition of the place you live but  if you have the money and you want to look after your engine you can change it as often as you like,you cant over do it because oil don't stay the same after its been use does not matter if its been used 10km or 10,000km number of cold start  condensation builds up which leads to water in the oil ,chemical properties changes and dirt gets in the oil which all result in poor engine lubrication


Oil and filter change


1.Warm the car up ( when car is warm the radiator fan should turn on)
2.Turn engine off
3.remove dip stick and oil cap
4.Put container under oil sump, remove sump plug
5.Leave it to drain for 15 to 20 min
6. replace washer on sump plug and do up plug
7.Replace oil filter
8.Fill up with engine oil look at service manual for exact litter for your car.


Over filling


Over filling can cause the rear and front bearing seal to break and leak because of the added pressure. Usually the rear seal will give way first which in most case you get oil in your flywheel and clutch and that is a very very bad thing.


Under filling


Under filling can also cause very bad things to happen to the engine. Engine unable to lubricate properly , heat forms quicker, engine ceasing .... to name a few


Correct Oil Level


Refer to owner/service manual or oil level should be in between the two dots/shaded area (min and max) on the dip stick.

Fuel filter

Fuel filter are there for filtering the fuel so dirt in the fuel and rust will not clog the injectors/ wear out the cylinder.

There are two types of fuel filter. A inline fuel filter and in tank fuel filter, in tank fuel filter is build into the fuel tank and is self cleaning it is made of mesh and steel wool. inline fuel filter should be changed every 50,000km but newer car are said to not need changing and should last a lifetime but nothing last  forever in practical, to check  if the fuel filter need replacing remove the fuel filter and blow through it if it is hard to blow it needs replacing.


Inline Fuel filter replacement

CAUTION: AFTER STEP 3 IF BATTERY IS NEXT TO FUEL FILTER DISCONNECT NEGATIVE(BLACK) LEAD
Steps

1.Start the car
2.Go to the fuse box and unplug the 15A FIE/M (circle in yellow in the picture) car should stop running after this
3.Crank the car a few times to make sure its fully de-pressurise then turn the key all the way off
4.Unscrew the 2 nuts underneath the fuel filter( in my case it way a 19mm top and a 14mm bottom)
5.Unscrew the top nut non the fuel filter (my case 17mm)
6.Unhook both fuel lines, some fuel might spill out  at this stage.Clean up any spill
7.Remove the fuel filter from the harness should be a bolt behind the filter
8. Replace the filter in reverse order (important replace washer, put them correct way on. flat side)
9. Start the car and check for leaks

Glow plugs

Glow plugs are only use on diesel engines. The heater tube on a glow plug heats up red hot in a mater of seconds (as you can see in the video bellow) and which then heats up the air coming from the intake.

Testing Glow plugs

Current draw  starts at 14A then decrease as it gets hotter to around 6A in 20 second.

Colour of plug goes red hot in just under a second.

The glow plugs we tested is in good condition. The glow plugs went red hot when connected to a car battery like it should.

Diesel injector

Diesel injectors are used on diesel engines to supply fuel to each cylinder.

This is a picture of a diesel injector in bits

To re-assemble the injector

1.Injector Bottom
2.Injector Nozzle
3.Needle Valve
4.Spacer
5.Spring Seat
6.Valve Spring
7.Shim
8.Injector Top


HOW THEY WORK

Fuel is pump through the injector gallery to pressure rise the injector when the correct pressure has build up in the injector the pressure pushes the tip of the needle valve back comprising the valve spring, in result spraying diesel fuel at high pressure out of the injector nozzle.


Diesel injector TEST

Here I am testing  the pressure of the injectors, if its up to service manual specification. In the video, the screen on the right  says that this injector is spraying at 128 bar and the machine display that it is a pass. So this injector is in good condition and don't need rebuilding. 

Military Phonetic Alphabet

A = Alfa
B = Bravo
C = Charlie
D = Delta
E = Echo
F = Foxtrot
G = Golf
H = Hotel
I = India
J = Juliett
K = Kilo
L = Lime
M = Mike
N = November
O = Oscar
P = Papa
Q = Quebec
R = Rome
S = Sierra
T = Tango
U = Uniform
V = Victor
W = Whiskey
X = Xray
Y = Yankee
Z = Zulu