The installer’s worst nightmare, repeat engine failures from a lack of proper diagnosis.
So, you have replaced an engine, cylinder head, or crankshaft in your vehicle. But, a short time later, you have repeat engine failures, for the same problem.
Consequently, not finding the original problem, can cause repeat engine failures, costing a ton of money and down time.
Repeat engine failures often occur, because the original underlying cause of the initial problem was never correctly diagnosed or addressed. That’s why repairing only the symptoms allows the true problem to persist. And, inevitably causes the new or rebuilt engine components to fail in the same way. Another common mistake in diagnostics is, falsely condemning a part, that is really just out of adjustment.
Common Sequence Of Events
Fixing The Damage, Not The Cause:
Replacing a blown head gasket without identifying and repairing the overheating issue. (faulty water pump, clogged radiator, or persistent leak) means the new gasket will also fail.
Ignoring The Root Of Lubrication Issues:
If an engine fails due to oil starvation, simply installing a new engine without addressing the root cause. Then, the new engine suffering the same fate.
Failing To Flush Contaminants:
A catastrophic failure can create metallic debris and other contaminants that circulate throughout the system. If the related systems are not thoroughly cleaned or replaced, the debris can damage the new components.
Incorrect Component Installation Or Incompatible Parts:
Using an incompatible replacement engine, incorrect parts, or making installation errors. Then, puts immediate, undue stress on the system, leading to premature failure.
Neglecting Supporting Systems:
Problems in related systems, such as a faulty fuel injector or a weak ignition system leading to misfires. Can place excessive stress on internal engine components. Causing them to break down repeatedly if the original fault is ignored.
Consequences of Improper Diagnosis
Significant Financial Loss:
Repeat engine repairs or replacements are costly, a burden that is often avoidable with a thorough initial diagnosis.
Extended Downtime:
The vehicle is out of commission multiple times, leading to inconvenience and potential additional costs for alternative transportation.
Safety Hazards:
An engine failure can occur at any time, including while driving, which poses a serious safety risk.
Accelerated Wear And Tear:
Undiagnosed minor issues force the engine to work harder. As a result, accelerating wear and tear on all components until another major failure occurs.
Prevention
The key to preventing repeat engine failures is a comprehensive diagnostic process. That identifies the original, underlying cause of the failure. Rather than just fixing the resulting damage.
This Involves, Thorough Inspection:
Beyond the immediate site of damage, a full inspection of all related systems (cooling, lubrication, fuel, electrical) is crucial.
Professional Expertise:
Relying on qualified technicians who follow proper diagnostic procedures is essential.
Quality Parts:
Using high-quality, compatible replacement parts.
Scheduled Maintenance:
Following the manufacturer’s recommended maintenance schedule helps identify and resolve minor issues before they escalate.
Not Diagnosing The Original Problem Properly
Computers and sensors control, almost all of today’s vehicles. So, any one of them failing, can also cause, repeat engine failures.
So, the engine, piston, or cylinder head is replaced. But, shortly after, the customer returns with the same, or a new problem. Because, finding and correcting the original problem, never did happen. And, quite often it’s a leaking or blown head gasket.
So, before replacing any of these components, you must first find the original problem that caused, the original failure.
Diagnostic Steps, To Avoid Repeat Engine Failures
Step-1
Verify the Problem
Before one minute is spent on diagnosis, be certain that a problem actually exists. Because, if the problem cannot be confirmed. Then, the problem cannot be solved or tested, to verify that the repair was complete.
Step-2
Perform a Thorough Visual Inspection and Basic Tests
The visual inspection is the most important aspect of diagnosis! Most experts agree, that most engine problems can be found, simply by performing a visual inspection.
Step-3
Retrieve the (DTC)
If a (DTC) is present in the computer memory, it should turn on a warning light. Commonly labelled “check engine” or “service engine soon.”
Step-4
Check for (TSB’s)
Check for corrections in bulletins, that match the symptoms. NOTE: (DTCs must be known, before searching for service bulletins. Because, bulletins often include information on solving problems, that involve a stored (DTC). And, some can cause, repeat engine failures.
Step-5
Look at Scan Tool Data
The best way to look at scan data, is in a definite sequence. Because, that can tell you the most about, the operation of the engine.
Step-6
Narrow the Problem Down, to a System or Cylinder
Consequently, narrowing the focus to a system or individual cylinder, is the hardest part of the entire diagnostic process.
Step-7
Determine the Root Cause, and Repair the Problem
Always follow the vehicle manufacturer’s recommendations, when you repair or replace any part. Also, follow manufacturers recommended repair procedures and methods.
Step-8
Verify the Repair, and Clear Any Stored (DTC)
Computers and sensors control today’s vehicles. So, there may be as many as, 20 sensors, feeding information to the vehicle computer.
And, there are also other sensors, while not directly attached to the computer, that do affect the information. Furthermore, these sensors are part of other systems, that allow the vehicle to operate properly. So, all of these systems, must be in proper operating order, for the engine to function properly. As a result, you risk, repeat engine failures.
Systems That Play An Important Role, In The Proper Running Of Today’s Engines Are:
- The exhaust system
- Cooling system
- Oiling system
- Fuel ignition system
- (EGR) system
- Air temperature system
- A.I.R. system
- (ECT) system
These systems are all controlled, by the sensors that send signals to the computer. So, the result of this information is, a properly or improperly operating engine. Consequently, failure of any of the sensors, or failure of the system itself, can cause an automotive engine failure.
So, just as with the original engine, it is reasonable to expect mileage from remanufactured engines of 100,000 miles. The difference then, is in the changing over of an engine or part.
In Summary: Repeat Engine Failures
So, the sensors/systems that provide information, to allow the engine to run properly, also have 100,000 miles on them.
Therefore, if you have not found the original problem, keep looking. Otherwise, you could end up with the installer’s worst nightmare, repeat engine failures.
Thank You!
