General Description
A crankcase ventilation system is used to consume crankcase vapors in the combustion process instead of venting them to atmosphere. Fresh air from the intake system is supplied to the crankcase, mixed with blow-by gases and then passed through a calibrated orifice into the intake manifold.
Scheme 1
The primary control is through the positive crankcase ventilation (PCV) orifice (1) which meters the flow at a rate depending on inlet vacuum. The PCV orifice is an integral part of the camshaft cover. If abnormal operating conditions occur, the system is designed to allow excessive amounts of blow by gases to back flow through the crankcase vent orifices (2, 4) into the intake system to be consumed by normal combustion.
There is a one way valve (3) in the intake manifold in order to prevent the crankcase from being pressurized by positive pressure in the intake manifold when the turbocharger is in operation. When the turbocharger is operational, the pressure in the intake manifold can exceed atmospheric pressure which, without the one way valve, would force oil and PCV gases out of the camshaft cover and into the induction system, via the hose to the camshaft cover. This can cause coking in the throttle body and induction system and can reduce the effectiveness of the combustion and charge air cooling systems. During normal operation the PCV gases are sucked into the air stream after the charge air cooler.
General Information
The LHU BioPower engine have engine components that are adapted to ethanol fuel.
EVAP System Operation
The evaporative emission (EVAP) control system limits fuel vapors from escaping into the atmosphere. Fuel tank vapors are allowed to move from the fuel tank, due to pressure in the tank, through the EVAP vapor tube, into the EVAP canister. Carbon in the canister absorbs and stores the fuel vapors. Excess pressure is vented through the vent hose and EVAP canister vent solenoid valve to the atmosphere. The EVAP canister stores the fuel vapors until the engine is able to use them. At an appropriate time, the engine control module (ECM) will command the EVAP purge solenoid valve ON, allowing engine vacuum to be applied to the EVAP canister. With the normally open EVAP canister vent solenoid valve OFF, fresh air is drawn through the vent solenoid valve and the vent hose to the EVAP canister. Fresh air is drawn through the canister, pulling fuel vapors from the carbon. The air/fuel vapor mixture continues through the EVAP purge tube and EVAP purge solenoid valve into the intake manifold to be consumed during normal combustion. The control module uses several tests to determine if the EVAP system is leaking or restricted.
Test Description
The numbers below refer to the step numbers on the diagnostic table.
2
The noise may not be engine related. This step is to verify that the engine is making the noise. If the engine is not making the noise do not proceed further with this table.
3
The noise may be an internal engine noise. Removing the drive belts one at a time and operating the engine for a brief period will verify the noise is related to the drive belt. When removing the drive belt the water pump may not be operating and the engine may overheat. Also DTCs may set when the engine is operating with the drive belts removed.
4
Inspect all drive belt pulleys for pilling. Pilling is the small balls or pills or it can be strings in the drive belt grooves from the accumulation of rubber dust.
6
Misalignment of the pulleys may be caused from improper mounting of the accessory drive component, incorrect installation of the accessory drive component pulley, or the pulley bent inward or outward from a previous repair. Test for a misaligned pulley using a straight edge in the pulley grooves across two or three pulleys. If a misaligned pulley is found refer to that accessory drive component for the proper installation procedure for that pulley.
10
Inspecting of the fasteners can eliminate the possibility that a wrong bolt, nut, spacer, or washer was installed.
12
Inspecting the pulleys for being bent should include inspecting for a dent or other damage to the pulleys that would prevent the drive belt from not seating properly in all of the pulley grooves or on the smooth surface of a pulley when the back side of the belt is used to drive the pulley.
14
This test is to verify that the drive belt tensioner operates properly. If the drive belt tensioner is not operating properly, proper belt tension may not be achieved to keep the drive belt from slipping which could cause a squeal noise.
15
This test is to verify that the drive belt is not too long, which would prevent the drive belt tensioner from working properly. Also if an incorrect length drive belt was installed, it may not be routed properly and may be turning an accessory drive component in the wrong direction.
16
Misalignment of the pulleys may be caused from improper mounting of the accessory drive component, incorrect installation of the accessory drive component pulley, or the pulley bent inward or outward from a previous repair. Test for a misaligned pulley using a straight edge in the pulley grooves across two or three pulleys. If a misaligned pulley is found refer to that accessory drive component for the proper installation procedure for that pulley.
17
This test is to verify that the pulleys are the correct diameter or width. Using a known good vehicle compare the pulley sizes.
19
Replacing the drive belt when it is not damaged or there is not excessive pilling will only be a temporary repair.
| Step | Action | Yes | No |
|---|---|---|---|
| Refer to BELT DRESSING CAUTION . DEFINITION: The following items are indications of chirping: A high pitched noise that is heard once per revolution of the drive belt or a pulley. Chirping may occur on cold damp start-ups and will subside once the vehicle reaches normal operating temp. DEFINITION: The following items are indications of drive belt squeal: A loud screeching noise that is caused by a slipping drive belt. This is unusual for a drive belt with multiple ribs. The noise occurs when a heavy load is applied to the drive belt, such as an air conditioning compressor engagement snapping the throttle, or slipping on a seized pulley or a faulty accessory drive component. DEFINITION: The following items are indications of drive belt whine: A high pitched continuous noise. The noise may be caused by an accessory drive component failed bearing. | |||
| 1 | Did you review the Drive Belt Symptom operation and perform the necessary inspections? | Go to Step 2 | Go to SYMPTOMS - ENGINE MECHANICAL |
| 2 | Verify that there is a chirping, squeal or whine noise. Does the engine make the chirping squeal or whine noise? | Go to Step 3 | Go to DIAGNOSTIC AIDS |
| 3 | Remove the drive belt. If the engine has multiple drive belts, remove the belts one at a time and perform the test below each time a belt is removed. Operate the engine for no longer than 30-40 seconds. Repeat this test if necessary by removing the remaining belt(s). Does the chirping, squeal or whine noise still exist? | Go to SYMPTOMS - ENGINE MECHANICAL | Go to Step 4 |
| 4 | If diagnosing a chirping noise, inspect for severe pilling exceeding 1/3 of the belt groove depth. If diagnosing a squeal or whine noise, proceed to step 13. Do the belt grooves have pilling? | Go to Step 5 | Go to Step 6 |
| 5 | Clean the drive belt pulleys with a suitable wire brush. Did you complete the repair? | Go to Step 20 | Go to Step 6 |
| 6 | Inspect for misalignment of the pulleys. Are any of the pulleys misaligned? | Go to Step 7 | Go to Step 8 |
| 7 | Replace or repair any misaligned pulleys. Did you complete the repair? | Go to Step 20 | Go to Step 8 |
| 8 | Inspect for bent or cracked brackets. Did you find any bent or cracked brackets? | Go to Step 9 | Go to Step 10 |
| 9 | Replace any bent or cracked brackets. Did you complete the repair? | Go to Step 20 | Go to Step 10 |
| 10 | Inspect for improper, loose or missing fasteners. Did you find the condition? | Go to Step 11 | Go to Step 12 |
| 11 | Refer to FASTENER CAUTION . Tighten any loose fasteners. Refer to FASTENER TIGHTENING SPECIFICATIONS (LDK, LHU) . Replace any improper or missing fasteners. Did you complete the repair? | Go to Step 20 | Go to Step 12 |
| 12 | Inspect for a bent pulley. Did you find the condition? | Go to Step 18 | Go to Step 19 |
| 13 | Inspect for an accessory drive component seized bearing or a faulty accessory drive component. If diagnosing a whine noise and the condition still exist, proceed to DIAGNOSTIC AIDS . Did you find and correct the condition? | Go to Step 20 | Go to Step 14 |
| 14 | Test the drive belt tensioner for proper operation. Refer to DRIVE BELT TENSIONER DIAGNOSIS . Did you find and correct the condition? | Go to Step 20 | Go to Step 15 |
| 15 | Inspect for the correct drive belt length. Did you find and correct the condition? | Go to Step 20 | Go to Step 16 |
| 16 | Inspect for misalignment of a pulley. Did you find and correct the condition? | Go to Step 20 | Go to Step 17 |
| 17 | Inspect for the correct pulley size. Did you find and correct the condition? | Go to Step 20 | Go to DIAGNOSTIC AIDS |
| 18 | Replace the bent pulley. Did you complete the repair? | Go to Step 20 | Go to Step 19 |
| 19 | Replace the drive belt. Refer to DRIVE BELT REPLACEMENT . Did you complete the repair? | Go to Step 20 | Go to DIAGNOSTIC AIDS |
| 20 | Operate the system in order to verify the repair. Did you correct the condition? | System OK | Go to Step 3 |
The numbers below refer to the step numbers on the diagnostic table.
2
This test is to verify that the symptom is present during diagnosing. Other vehicle components may cause a similar symptom.
3
This test is to verify that one of the drive belts is causing the rumbling noise or vibration. Rumbling noise may be confused with an internal engine noise due to the similarity in the description. Remove only one drive belt at a time if the vehicle has multiple drive belts. When removing the drive belts the water pump may not be operating and the engine may overheat. Also DTCs may set when the engine is operating with the drive belts removed.
4
Inspecting the drive belts is to ensure that they are not causing the noise. Small cracks across the ribs of the drive belt will not cause the noise. Belt separation is identified by the plys of the belt separating and may be seen at the edge of the belt our felt as a lump in the belt.
5
Small amounts of pilling is normal condition and acceptable. When the pilling is severe the drive belt does not have a smooth surface for proper operation.
9
Inspecting of the fasteners can eliminate the possibility that a wrong bolt, nut, spacer, or washer was installed.
11
This step should only be performed if the water pump is driven by the drive belt. Inspect the water pump shaft for being bent. Check also the water pump bearings. They should run smoothly and not have an excessive clearance. Compare the water pump with a known good water pump.
12
Accessory drive component brackets that are bent, cracked, or loose may put extra strain on that accessory component causing it to vibrate.
| Step | Action | Yes | No |
|---|---|---|---|
| Refer to BELT DRESSING CAUTION . DEFINITION: The following items are indications of drive belt rumbling: A low pitch tapping, knocking, or thumping noise heard at or just above idle. Heard once per revolution of the drive belt or a pulley. Rumbling may be caused from: Pilling, the accumulation of rubber dust that forms small balls (pills) or strings in the drive belt pulley groove The separation of the drive belt A damaged drive belt DEFINITION: The following items are indications of drive belt vibration: The vibration is engine-speed related. The vibration may be sensitive to accessory load. | |||
| 1 | Did you review the Drive Belt Symptom operation and perform the necessary inspections? | Go to Step 2 | Go to SYMPTOMS - ENGINE MECHANICAL |
| 2 | Verify that there is a rumbling noise or that the vibration is engine related. Does the engine make the rumbling noise or vibration? | Go to Step 3 | Go to DIAGNOSTIC AIDS |
| 3 | Remove the drive belt. If the engine has multiple drive belts, remove the belts one at a time and perform the test below each time a belt is removed. Operate the engine for no longer than 30-40 seconds. Repeat this test if necessary by removing the remaining belt(s). Does the rumbling or vibration still exist? | Go to SYMPTOMS - ENGINE MECHANICAL or VIBRATION ANALYSIS - ENGINE | Go to Step 4 |
| 4 | Inspect the drive belts for wear, damage, separation, sections of missing ribs, and debris build-up. Did you find any of these conditions? | Go to Step 7 | Go to Step 5 |
| 5 | Inspect for severe pilling of more than 1/3 of the drive belt pulley grooves. Did you find severe pilling? | Go to Step 6 | Go to Step 7 |
| 6 | Clean the drive belt pulleys with a suitable wire brush. Reinstall the drive belts. Refer to DRIVE BELT REPLACEMENT . Did you correct the condition? | Go to Step 8 | Go to Step 7 |
| 7 | Install a new drive belt. Refer to DRIVE BELT REPLACEMENT . Did you complete the replacement? | Go to Step 8 | Go to Step 9 |
| 8 | Operate the system in order to verify the repair. Did you correct the condition? | System OK | Go to Step 9 |
| 9 | Inspect for improper, loose or missing fasteners. Did you find any of these conditions? | Go to Step 10 | Go to Step 11 |
| 10 | Refer to FASTENER CAUTION . Tighten any loose fasteners. Refer to FASTENER TIGHTENING SPECIFICATIONS (LDK, LHU) . Replace improper or missing fasteners. Did you complete the repair? | Go to Step 13 | Go to Step 11 |
| 11 | Inspect the water pump shaft for being bent. Did you find and correct the condition? | Go to Step 13 | Go to Step 12 |
| 12 | Inspect for bent or cracked brackets. Did you find and correct the condition? | Go to Step 13 | Go to DIAGNOSTIC AIDS |
| 13 | Operate the system in order to verify the repair. Did you correct the condition? | System OK | Go to Step 3 |
The numbers below refer to the step numbers on the diagnostic table.
2
This inspection is to verify the condition of the drive belt. Damage may of occurred to the drive belt when the drive belt fell off. The drive belt may of been damaged, which caused the drive belt to fall off. Inspect the belt for cuts, tears, sections of ribs missing, or damaged belt plys.
4
Misalignment of the pulleys may be caused from improper mounting of the accessory drive component, incorrect installation of the accessory drive component pulley, or the pulley bent inward or outward from a previous repair. Test for a misaligned pulley using a straight edge in the pulley grooves across two or three pulleys. If a misaligned pulley is found refer to that accessory drive component for the proper installation procedure for that pulley.
5
Inspecting the pulleys for being bent should include inspecting for a dent or other damage to the pulleys that would prevent the drive belt from not seating properly in all of the pulley grooves or on the smooth surface of a pulley when the back side of the belt is used to drive the pulley.
6
Accessory drive component brackets that are bent or cracked will let the drive belt fall off.
7
Inspecting of the fasteners can eliminate the possibility that a wrong bolt, nut, spacer, or washer was installed. Missing, loose, or the wrong fasteners may cause pulley misalignment from the bracket moving under load. Over tightening of the fasteners may cause misalignment of the accessory component bracket.
13
The inspection is to verify the drive belt is correctly installed on all of the drive belt pulleys. Wear on the drive belt may be caused by mis-positioning the drive belt by one groove on a pulley.
14
The installation of a drive belt that is too wide or too narrow will cause wear on the drive belt. The drive belt ribs should match all of the grooves on all of the pulleys.
15
This inspection is to verify the drive belt is not contacting any parts of the engine or body while the engine is operating. There should be sufficient clearance when the drive belt accessory drive components load varies. The drive belt should not come in contact with an engine or a body component when snapping the throttle.
| Step | Action | Yes | No |
|---|---|---|---|
| Refer to BELT DRESSING CAUTION . DEFINITION: The drive belt falls off the pulleys or may not ride correctly on the pulleys. DEFINITION: Wear at the outside ribs of the drive belt due to an incorrectly installed drive belt. | |||
| 1 | Did you review the Drive Belt Symptom operation and perform the necessary inspections? | Go to Step 2 | Go to SYMPTOMS - ENGINE MECHANICAL |
| 2 | If diagnosing excessive wear, proceed to step 13. If diagnosing a drive belt that falls off, inspect for a damaged drive belt. Did you find the condition? | Go to Step 3 | Go to Step 4 |
| 3 | Install a new drive belt. Refer to DRIVE BELT REPLACEMENT . Does the drive belt continue to fall off? | Go to Step 4 | System OK |
| 4 | Inspect for misalignment of the pulleys. Did you find and repair the condition? | Go to Step 12 | Go to Step 5 |
| 5 | Inspect for a bent or dented pulley. Did you find and repair the condition? | Go to Step 12 | Go to Step 6 |
| 6 | Inspect for a bent or a cracked bracket. Did you find and repair the condition? | Go to Step 12 | Go to Step 7 |
| 7 | Inspect for improper, loose or missing fasteners. Did you find loose or missing fasteners? | Go to Step 8 | Go to Step 9 |
| 8 | Refer to FASTENER CAUTION . Tighten any loose fasteners. Refer to FASTENER TIGHTENING SPECIFICATIONS (LDK, LHU) . Replace improper or missing fasteners. Does the drive belt continue to fall off? | Go to Step 9 | System OK |
| 9 | Test the drive belt tensioner for proper operation. Refer to DRIVE BELT REPLACEMENT . Does the drive belt tensioner operate correctly? | Go to Step 11 | Go to Step 10 |
| 10 | Replace the drive belt tensioner. Refer to DRIVE BELT REPLACEMENT . Does the drive belt continue to fall off? | Go to Step 11 | System OK |
| 11 | Inspect for failed drive belt idler and drive belt tensioner pulley bearings. Did you find and repair the condition? | Go to Step 12 | Go to DIAGNOSTIC AIDS |
| 12 | Operate the system in order to verify the repair. Did you correct the condition? | System OK | Go to Step 2 |
| 13 | Inspect the drive belt for the proper installation. Refer to DRIVE BELT REPLACEMENT . Did you find this condition? | Go to Step 16 | Go to Step 14 |
| 14 | Inspect for the proper drive belt. Did you find this condition? | Go to Step 16 | Go to Step 15 |
| 15 | Inspect for the drive belt rubbing against a bracket, hose, or wiring harness. Did you find and repair the condition? | Go to Step 17 | Go to DIAGNOSTIC AIDS |
| 16 | Replace the drive belt. Refer to DRIVE BELT REPLACEMENT . Did you complete the replacement? | Go to Step 17 | |
| 17 | Operate the system in order to verify the repair. Did you correct the condition? | System OK | |
Valve Measurement and Reconditioning Overview
- Proper valve service is critical to engine performance. Therefore, all detailed measurement procedures must be followed to identify components that are out of specification.
- If the measurement procedures reveal that the valve or valve seat must be reconditioned, it is critical to perform the measurement procedures after reconditioning.
Scheme 2
Scheme 3
- Measure the valve seat width in the cylinder head using a proper scale.
- Measure the seat width (b) on the valve face (1) using a proper scale.
- NOTE: The seat contact area must be at least 0.5 mm (0.020 in) from the outer diameter, margin (a), of the valve. If the contact area is too close to the margins, the seat must be reconditioned to move the contact area away from the margin. Compare your measurements with the specifications listed in «ENGINE MECHANICAL SPECIFICATIONS (LDK, LHU)»(ref-653636-S28533554622014090100000) .
- If the seat widths are acceptable, check the valve seat roundness using the Valve Seat Roundness Measurement Procedure.
- If the seat width is not acceptable, you must grind the valve seat using the Valve and Seat Reconditioning Procedure to bring the width back into specification. Proper valve seat width is critical to providing the correct amount of valve heat dissipation.