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Engine Troubleshooting Guide
Shortcuts to Costly Engine Diagnostics Includes Sections on: • Low Power and Uneven Running • High Oil Temperature • Excess Oil Consumption • Engine Stops • High Cylinder Head Temperature • Engine Misses • Causes of Excessive Carbon Deposit • A “TooͲRich Mixture” • A “TooͲLean Mixture” • and many others
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Engine Troubleshooting Guide
Table of Contents
Engine Troubleshooting Guide ......................................... 4 Table of Contents ............................................................. 4 Failure of Engine to Start .................................................. 2 Low Power and Uneven Running ..................................... 3 High Oil Temperature ....................................................... 4 Excess Oil Consumption ................................................... 4 Low Oil Pressure ............................................................... 5 High Oil Pressure .............................................................. 5 Improper Engine Acceleration .......................................... 6 Failure of Engine to Idle Properly ..................................... 6 Failure of Engine to Develop Full Power .......................... 7 Engine Stops ..................................................................... 8 Engine Vibrates Excessively .............................................. 8 Engine Continually Throws Alternator Belt ...................... 9 Engine Overheats ............................................................. 9 High Cylinder Head Temperature ..................................... 9 Engine Won’t Stop When Switch is Turned Off .............. 10 Carburetor Leaks Fuel .................................................... 10 Engine “Spits Back” in Carburetor .................................. 10 Engine Misses Intermittently ......................................... 11 Engine Misses Regularly ................................................. 11 Scattering Misfire ........................................................... 12 Single Cylinder Miss at High Speed ................................ 12 Single Cylinder Miss at Low Speed ................................. 12 Causes of PreͲIgnition .................................................... 13 Causes of Excessive Carbon Deposit .............................. 13 Magneto Fails to Deliver any Spark ................................ 13 Crankcase Fills with Oil (DryͲsump System) ................... 13 Engine Pumps Oil ............................................................ 14 Faulty Spark .................................................................... 14 Mixture Analysis by Exhaust Flame ................................ 15 A “TooͲRich Mixture” may be caused by: ....................... 15 A “TooͲLean Mixture” may be caused by: ...................... 15 Notes .............................................................................. 16 ECi® Technical Reference Materials ................................ 17
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Engine Troubleshooting Guide
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Failure of Engine to Start 27 points 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27.
Lack of fuel Ignition switch off UnderͲpriming or overͲpriming Incorrect throttle setting Cold oil Defective battery (battery ignition systems) Dirty or defective spark plugs Water in magneto Wet ignition harness Wrong grade of fuel Spark advance retarded too far Vapor in fuel system Water in carburetor Defective ignition wiring Booster magneto defective Incorrect valve and/or ignition timing Defective magneto Broken impulse coupling Magneto breaker points defective Incorrect valve clearance Defective priming system Internal trouble in carburetor Intake manifold air leaks Broken, shredded or defective camshaft Internal engine failure Spark plug wires crossed Miscellaneous (turn engine over slowly by hand with the master & magneto switch off and note any unusual condition, particularly low compression.
800ͲECiͲ2FLY (800Ͳ324Ͳ2359) • 210Ͳ820Ͳ8101 • www.eci.aero
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3
Engine Troubleshooting Guide
Low Power and Uneven Running 29 points 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29.
Mixture too rich or too lean Leaks in induction system Defective or fouled spark plugs and loose plug connections Improper fuel grades Wet or defective ignition wiring Engine overheating Defective magneto breaker points Dirty or broken carbon brushes in magneto Improper valve and/or ignition timing Propeller out of track, or hub nut loose Carburetor heat control malfunction Cracked engine mount or loose mount bolts Foreign matter in induction system or fuel lines Incorrectly adjusted carburetor control linkage Fuel feed valve leaking or not operating properly Warped or burned valves or valve seats Broken valve springs Worn or sticking pistons or cylinders Cracked pistons or cylinders Bent pushrods Cylinder gaskets blown Magneto ground wire loose and grounding Carburetor icing Fluctuating fuel pressure Defective rocker arms or bearings Defective valve guides Bent crankshaft Crosswind on propeller during ground operation Spark plug wires crossed
Š2011
Engine Components International
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Engine Troubleshooting Guide
High Oil Temperature 12 points 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.
Insufficient oil supply Defective oil temperature gauge Airflow through oil cooler blocked Oil cooler bypass valve malfunction Cylinder baffles missing or insecure Poor airflow around oil tank Clogged oil lines or screens Overheated bearings Dirty or improper grade of oil Improper grade of fuel Improper ignition timing Main bearing shifting in crankcase bearing bore.
Excess Oil Consumption 9 points 1. 2. 3. 4. 5. 6. 7. 8. 9.
Improper grade of oil Improper venting of oil system Piston rings worn, broken or incorrectly installed Breather line exiting in low pressure area and blocked or missing vacuum break hole on breather line Cracked pistons Defective supercharger seal Piston oil drain holes clogged Oil pressure too high Too much clearance between intake valve and guide
800ͲECiͲ2FLY (800Ͳ324Ͳ2359) • 210Ͳ820Ͳ8101 • www.eci.aero
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Engine Troubleshooting Guide
Low Oil Pressure 18 points 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18.
Insufficient oil supply Oil pump not primed Improper setting of pressure relief valve Foreign matter in relief valve Defective pressure gauge, or clogged gauge line Improper grade of oil High oil temperature Leak in suction lines Dirt in oil screens Foaming in oil tank Oil congealed in intake line Excessively diluted oil Broken oil line Excessive cam follower to crankcase clearance Excessive bearing clearance or wrong undersize bearings Crankshaft plugs leaking or missing Worn oil pump gears Broken oil pump gears or drive shaft
High Oil Pressure 8 points 1. 2. 3. 4. 5. 6. 7. 8.
Improper grade of oil Pressure relief valve stuck closed or improperly adjusted Oil cold or frozen Oil pipe bent or crushed Defective pressure gauge Insufficient bearing clearance Oil Screen or filter clogged Bearing tight due to engine overheating
Š2011
Engine Components International
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Engine Troubleshooting Guide
Improper Engine Acceleration 11 points 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
Incorrectly adjusted carburetor Defective accelerating pump Cold oil Defective tachometer Improper propeller pitch or warped propeller Improper throttle or mixture control linkage adjustment Fuel valve leaking or not operating properly Improper spark adjustment Improper engine timing Internal carburetor trouble, or pressureͲtype carburetor in gravity fuel system 11. Air leaks or restriction in induction system
Failure of Engine to Idle Properly 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20.
20 points Carburetor control linkage improperly adjusted Loose spark plug connectors Water or oil in magnetos Burned or pitted contact breaker points Improper magneto timing Defective ignition harness Improper grade of fuel Incorrect idling speed adjustment Throttle valve closing too far Idling jet restricted Air leaks in induction system Vapor in fuel system Improper fuel pressure Internal carburetor trouble Partial obstruction in fuel lines Fuel valve leaking or not operating properly Defective primer valve Improper valve clearance Low cylinder compression Excessive play in carburetor control linkage
800ͲECiͲ2FLY (800Ͳ324Ͳ2359) • 210Ͳ820Ͳ8101 • www.eci.aero
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Engine Troubleshooting Guide
Failure of Engine to Develop Full Power 29 points 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29.
Carburetor control linkage improperly adjusted Mixture too lean or too rich Throttle valve not fully open Improper grade of fuel Air leak in carburetor Incorrect fuel pressure Improper valve clearance Improper grade of oil Oil too hot or too cold Rocker arms not properly lubricated Incorrect valve or ignition timing Defective spark plugs Weak magneto magnets Burned or pitted contact breaker points Excessive carbon and preͲignition Intake manifold too cold Pressure type carburetor in gravity system Weak or broken valve springs Low cylinder compression Valve seats scored or worn Bent pushrods Excessive back pressure from exhaust manifold Engine stiff or tight Incorrect propeller setting, or warped propeller blades Engine overheating Carburetor venturi too small Carburetor icing Improper grade of fuel Defective supercharger
Š2011
Engine Components International
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Engine Troubleshooting Guide
Engine Stops 12 points 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.
Magnetos grounded Out of fuel Carburetor jets restricted Air or vapor lock in fuel line Fuel lines partially obstructed Foreign object in induction system Water in fuel Broken fuel lines Sheared timing gears Internal structural failure Propeller contacts solid object Air vent or fuel tank obstructed
Engine Vibrates Excessively 11 points 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.
Propeller out of balance or out of track Bent crankshaft Unequal valve clearance Defective spark plugs Engine loose on mount Propeller hub nut loose Carburetor icing Incorrect carburetor setting Engine too cold Improper ignition timing Worn dynamic dampner bushings or pins
800ͲECiͲ2FLY (800Ͳ324Ͳ2359) • 210Ͳ820Ͳ8101 • www.eci.aero
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Engine Troubleshooting Guide
Engine Continually Throws Alternator Belt 3 points 1. 2. 3.
Bent pulley Alternator bearings or armature Worn dynamic dampner bushings or pins
Engine Overheats 15 points 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15.
Retarded spark or spark timed late Defective water circulation Defective oil circulation Thin oil Lean Mixture Camshaft out of time Idling engine too long Running air cooled engine on ground too long Insufficient oil cooling Insufficient oil supply Running engine with radiator or cowling shutters closed Excessive carbon Engine improperly cowled Overheated bearing Tight bearings or pistons out of line
High Cylinder Head Temperature 15 points 1. 2. 3. 4. 5. 6.
Mixture too lean Improper grade of fuel Air leaks in induction system High carburetor air inlet temperature Magnetos improperly timed Damaged cylinder baffles, fins, or restrictions in airflow
Š2011
Engine Components International
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Engine Troubleshooting Guide
7. 8. 9. 10. 11. 12. 13. 14. 15.
Incorrect valve operation or clearance Restrictions in exhaust system Temperature gauge defective Thermocouple wires too close to exhaust manifold Spark retarded PreͲignition through carbon or defective spark plugs Warped valves Loose valve seats and guides Worn valve guides
Engine Won’t Stop When Switch is Turned Off 4 points 1. 2. 3. 4.
Magneto ground wires loose or broken Faulty magneto switch Engine excessively hot Incandescent carbon in cylinders
Carburetor Leaks Fuel 6 points 1. 2. 3. 4. 5. 6.
Leaky or stuck float Excessive fuel supply pressure Poor seating of needle valve Worn float fulcrum pin Improper float level Loose needle valve seat
Engine “Spits Back” in Carburetor 13 points 1. 2. 3. 4. 5.
Cold engine or cold mixture Lean mixture Air leaks in manifold Air leaks around intake valve stems Weak valve springs
800ͲECiͲ2FLY (800Ͳ324Ͳ2359) • 210Ͳ820Ͳ8101 • www.eci.aero
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Engine Troubleshooting Guide
6. 7. 8. 9. 10. 11. 12. 13.
Sticking valves Spark plug wires crossed or incorrectly connected Ignition out of time or retarded Camshaft out of time Overheating Carbon Improper grade of fuel Water in gasoline
Engine Misses Intermittently 13 points 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.
Incorrect mixture Improper grade of fuel Water in fuel Air leaks in induction system Slow valve action Defective magnetos or ignition harness Distributor points or contact breaker points dirty or pitted Carburetor air heater defective High oil temperature Defective spark plugs Improper timing Carburetor icing Magneto ground wire swinging and periodically grounding
Engine Misses Regularly 6 points 1. 2. 3. 4. 5. 6.
Fouled spark plug Defective spark plug Broken or grounded spark plug wire Improper valve clearance Low compression on one or more cylinders Damaged magneto distributor head
Š2011
Engine Components International
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Engine Troubleshooting Guide
Scattering Misfire 12 points 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.
Lean mixture Rich mixture Water in gasoline Air leak in intake manifold Intake valve holding open Sticky valve guides Weak valve springs Excessive breaker point clearance Weak breaker arm spring Excessive rotor contact gap clearance Moisture on distributor block Faulty spark
Single Cylinder Miss at High Speed 6 points 1. 2. 3. 4. 5. 6.
Short circuited spark plugs Short circuited spark plug wire Short circuited distributor block Spark plug gap too wide Weak exhaust valve springs Insufficient valve tappet clearance
Single Cylinder Miss at Low Speed 7 points 1. 2. 3. 4. 5. 6. 7.
Short circuited spark plug Short circuited spark plug wire Short circuited distributor block Wrong spark plug gap Weak compression Air leak around intake valve stem Weak exhaust valve spring
800ͲECiͲ2FLY (800Ͳ324Ͳ2359) • 210Ͳ820Ͳ8101 • www.eci.aero
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Engine Troubleshooting Guide
Causes of PreͲIgnition 5 points 1. 2. 3. 4. 5.
Carbon Overheating Excessively rich mixture Ignition out of time Spark plug wires crossed or connected to wrong cylinder
Causes of Excessive Carbon Deposit 5 points 1. 2. 3. 4. 5.
Engine flooded with oil Worn piston rings Inferior quality of engine oil Rich mixture Engine operated for long period without cleaning carbon
Magneto Fails to Deliver any Spark 4 points 1. 2. 3. 4.
Primary circuit grounded or open Secondary circuit grounded or open Ground wire or switch grounded Condenser circuit open or shorted, or condenser punctured
Crankcase Fills with Oil (DryͲsump System) 6 points 1. 2. 3. 4. 5. 6.
Scavenger pump has lost its prime Scavenger pump screen stopped up Scavenger suction or pressure lines stopped up Air leak in suction side of scavenger pump Broken scavenger pump drive Scavenger pump badly worn
©2011
Engine Components International
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Engine Troubleshooting Guide
Engine Pumps Oil 10 points 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
Piston rings poor fit in piston grooves Piston rings poor fit in cylinder Broken piston rings Scored cylinder walls Excessive piston clearance Excessive oil pressure Thin oil Improper grade of oil Excessive bearing clearance Faulty scavenger pump
Faulty Spark 19 points 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19.
Breaker point clearance incorrect Breaker points burned or dirty Collector brush worn out or dirty Distributor brush worn out or dirty Distributor segments/rotor contact corroded or burnt Collector ring short circuited or dirty Distributor rotor short circuited or dirty Incorrect EͲgap Primary winding short circuited or dirty Secondary winding short circuited or burned out Condenser short circuited or punctured Magnets weak or crossed Loose or corroded connection within the magneto Ground wire or switch short circuited Moisture within the magneto Armature touches pole pieces Foreign material collected on armature Defective spark plugs Carbon tracks resulting from flashover caused by moisture.
800ͲECiͲ2FLY (800Ͳ324Ͳ2359) • 210Ͳ820Ͳ8101 • www.eci.aero
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Engine Troubleshooting Guide
Mixture Analysis by Exhaust Flame 4 points 1. 2. 3. 4.
Rich Mixture: Long deep blue flame with red tip, black smoke. Lean Mixture: Short irregular light blue flame with yellow tip. Proper Mixture: Quick blue flame without yellow tip. Oil pumping is shown by blue exhaust smoke.
A “TooͲRich Mixture” may be caused by: 6 points 1. 2. 3. 4. 5. 6.
High fuel pressure Oil in cylinders Carburetor float valve seating improperly Float leaking air Jet gaskets of improper thickness or out of shape Float level too high (these troubles would be responsible for the carburetor flooding and a rich mixture, particularly at low speeds)
A “TooͲLean Mixture” may be caused by: 9 points 1. 2. 3. 4. 5. 6. 7. 8. 9.
Insufficient fuel in tank Partially clogged fuel line Insufficient air pressure in pressure fuel tank Air vent on fuel tank clogged Fuel filter or jets clogged Carburetor float level too low Water in carburetor or system Air leaks in induction system Sticking valves
©2011
Engine Components International
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