1

Tune up tlla wjiah jkqfha wehs

1) tkacsu Pickup uos jQ úg¡

2) bkaOk l%shdldß;ajh wvq jQ úg¡

3) ÿu jeä jQ úg¡

4) tkacsu ñia lsßu ksid¡

5) iEu 20000Km miq

Tune up tlla lsßu u.ska lrkqfha mQ¾K oykhla isÿlsßug wjiah

bkaOk jdhq ñY%Kh ieliSuhs¡

2

Engine Tune up tlla lsßug m%:u isÿ l,hq;= oe

1) Engine ys Compression w.h mßlaId lsßu

2) Head bolt kshu mßos ;oú we;soehs mßlaId lsßu

3) Valve clearance kshu mßos ilia lsßu

4) Cooling system mßlaId lsßu

5) Lubrication system mßlaId lsßu

6) Fuel system mßlaId lsßu

7) Electrical system mßlaId lsßu

8) Inlet yd Exhaust system mßlaId lsßu

9) Ignition timing kshu mßos ilia lsßu

10) Drive belt mßlaId lsßu

3

Compression Test

Dry Compression Test

1) Battery fydo ;;ajfha ;sfnoehs ne,su¡ 2) Drive belt fydo ;;ajfha ;sfíoehs ne,su¡ 3) j;=r " Ths,a ldkaÿ ;sfíoehs ne,su¡ 4) Petrol Engine tl l%shd ldß WIaK;ajhg tk;=re mk.kaj ;sìh

hq;=h¡ 5) Air Cleaner tl .e,ùu¡ 6) Head bolt ksIamdlh os we;s w.hg ;o l, hq;=h¡ tkcsu mk

.ekaúug fkdyelskï ksIamdlh Cold wjia:dfõ os we;s w.hg ;o

l< hq;=h¡ 7) Valve Clearance mßCIdj¡ 8) tkacsu iagdÜ fkdúug j.n,d .eksu¡ Fuel cut ( Fuel cut off

solenoid l%shd úrys;) lsßu¡ 9) Ignition Cut cut (Distributor tlg we;s jh¾ .,jd bj;a lsßu) 10) Spark plug ish,a, .e,úu¡ 11) Compression Test WmlrKh Spark plug iú ù ;snq ia:dkj,g

iïnkao lsßu¡

12) Accelerator tl fiñka Wmßu jrla m.d w;eßu¡

13) Stroke 5la 7la muk fudagrh l%shd;aul lsßu¡ 14) Compression WmlrKfha w.h lshjd .ekSu¡

4

4G32 Engine compression test result Cylinder No 1 2 3 4

Pressur

Kg/cm

13 13 13 13

Compression Test lsßug úfYaIs; WmlrKhla ndú;d lrhs¡ th Compression Gauge kï fõ¡

Compression Gauge

Compression gauge WmlrKfhka Spark plug iúfldg ;snq ;ekg

iïnkao fldg mßlaId lsßfuos tys w.h nd¾ 10;a 16;a w;r w.hl ;sìh hq;=h¡

m,uq msiagkfha Compression w.h yd fojk fyd wkla msiagka j,

Compression w.h w;r nd¾ 2g jvd jeä fjkila we;akï tkacsfï Vibration we;¡

nd¾ 10g jvd wvq Compression w.hla ;sfíkï tkacsfï fodaIhla we;

(f.úula)¡ th Piston rings f.úula ksid úh yel¡ th ksjerosj yÿkd.eksug

Wet Compression text tllg hd hq;=h¡

5

Wet Compression text

Spark plug iúù ;snq ia;dkfhka is,skavrh ;=,g Ths,a iaj,amhla oeñh

hq;=h túg Piston rings w;rg Ths,a f.dia ;rul Seal úula isÿfõ¡

kej;;a Compression gauge WmlrKh iïnkao fldg mßlaId fldg

ne,sh hq;=h¡ Compression w.h jeä úula we;kï Piston rings j, fodaIhla

we;¡ tfia lsisÿ fjkila fkdjkafkakï fjk;a fodaIhla ksid úh yel¡ fodaIhla

we;skï Tune up tllg fmr fodaIh idod.; hq;= fõ¡

Head bolt ;o lsßu

ksIamdolhd úiska os we;s w.hg (Torque) ueo isg fomig l;sr yevhg

fyd ksIamdolh os we;s wdldrhg ;o l< hq;=h¡ ksIamdolhd úiska Cold yd Hot hkqfjka w.hka folla os we;¡

6

Valve clearance ielisu¡

Valve clearance ;eìu ioyd Crank shaft tl ol=Kg lrljñka m,uq

is,skavrh ;=, n,myr wdrïN jkfia .eksug y;rjk is,skavrh Over lap l<

hq;=h¡ fuu wjia:dfõ Cam shaft sprocket i,l=K yd Cylinder head i,l=K

iumd; jkq,efí¡

fuu m,uq wjia:dfõ jE,aj mr;rhka iSreudr l< yelafla my;

oelafjk jE,ajhkah

fojk wjia:dfõ y;rjk is,skavrh n,myr wdrïN jkfia .eksug

Crank shaft tl ol=Kg jghla lrljñk m,uq is,skavrh Over lap l< hq;=h

fuu fojk wjia:dfjysos my; oelafjk jE,ajhkaf. jE,aj mr;rhka iSreudr

l< yelsh¡

Valve clearance

Standard value cold endine Intake 0.07mm Exhaust 0.17mm

Standard value on hot engine Intake 0.15mm Exhaust 0.25mm Adjusting valve clearance

1 2 3 4

I E I E I E I E 1st X X X X

2nd X X X X

7

Cooling system mßlaId lsßu¡

Coolant leak mßlaId lsßu

m%Odk jYfhka Coolant leak jk ia:dk lsysmhla we;¡ tkï

A worn seal on the water pump shaft can leak coolant

8

This radiator is badly corroded and is not worth fixing

Pinch hoses to check for age cracks, hardening, soft spots, blisters or bulges.

Head gasket damage can leak coolant

9

A cracked cylinder head can leak coolant inside the engine.

fuu m%Odk ia:dk lsysmh fydoska mßlaId lr ne,sh hq;=h¡ bkamiq

Radiator pressure test kit tl Radiator cap tl iújk ia:dkhg

iúfldg pressure fldg leak mßlaId fldg ne,sh hq;=h¡ Coolant level tl;a mßlaId fldg ne,sh hq;=h

10

Thermostat valve mßlaId lsßu

by; rEmfha mßos wmlrK ilia lrf.k Valve tl nÿfka fkd.efjk

mßos t,a,d Ndckh r;afldg WIaK;aj udkhlska c,fha WIaK;ajh mßlaId

lrñka Valve tl ksIamdolh ioykafldg we;s WIaK;ajfhaos újD; fõoehs

mßlaIdfldg ne,sh hq;=h¡

tkacsu mk.ekajq úg blaukska ls%hdldß WIaK;ajhg m;alr .eksu;a tu

ls%hdldß WIaKd;ajh taldldÍj mj;ajd .eksu;a Thermostat valve tflka

isÿflf¾

11

Radiator Cap mßlaId lsßu

c,fha ;dm wxlh (Boling point) 100ºc tu ksid r:hl l%shdldß

WIaK;ajh tu .kg jvd jeä lr.; fkdyels úh¡ tkacsfï fuu ls%shdldß

WIaK;ajh ;j;a by, .ekaúugkï c,fha :dm wxlh ;j;a by, .ekaúh

hq;=h¡ øjlhl msvkh jeäfjk úg tys ;dm wxlho by, hhs¡ c,fha idudkaH

jdhqf.da,Sh msvkh hgf;a :dm wxlh 100ºc jqjo¡ tys msvkh nd¾ tllska

jeäl, úg :dm wxlh 20ºc muk by, oeñh yelsh¡ tu ksid fu ioyd fhÿ

Wml%uh jkqfha Radiator pressure cap tl fhoSuhs¡

Radiator pressure cap tl ks¾udKh lrkqfha pressure relief valve

tlla yd Vacuum vent valve iu.ska Radiator pressure cap tlys by, we;s

.EialÜ tl u.ska Cap tl Radiator tlg iúlsßu;a iu. ia:Srju Radiator

lgg isrfõ¡ my,ska we;s .EialÜ tl Radiator gexlshg Spring iu. ysrùfuka

th pressure relief valve tlla f,i ls%hdlrhs Radiator esteem pressure

isudj blaujd jeäfjk úg fuu Relief valve tl tiú msgr k,h yryd jeä

msvkh ksoyia fõ¡ kej; Radiator tl isis,a ùfuos we;sjk ßla;h

je,elaúug Vacuum vent valve tlla fhdod we;¡ tu.ska wjg jdhqj weos

weú;a ßla;h ke;slrhs¡

Radiator pressure cap tl mßlaId lsßfuos tys iS,a j, m¨ÿ úï mßlaId

lr ne,sh hq;=h¡ bkamiq Radiator pressure test kit WmlrKh Radiator

pressure cap tlg kshñ; fldgia fhdod iúfldg pressure lr tys ldkaÿúï

we;soehs ne,sh yel¡

12

Drve Belt mßlaId lsßu

Drve Belt j,g ydks isÿú we;soehs ne,sh hq;=h tfia fkdue;skï kshñ;

Tension tfla we;soehs ne,sh hq;=h¡ w.s,af,ka ;ol< úg w.,la muk tfnkï

th kshñ; Tension we;shehs is;shyel¡

13

Cooling fan mßlaId lsßu

kdùk r: jdyk j, úúO Cooling fan j¾. we;¡ tkï

Crank shaft tfla lerl=ï n,fhka V-belt u.ska t,jkq ,nk tkacska

WIaK;ajh wkqj l%shdlrk Fan j¾.¡

tkacsfï WIaK;ajh yd tkacska fõ.h u.ska m,kh lrkq ,nk úÿ,s

fudag¾ u.ska t,jqï ,nd.kakd Fan j¾.¡

Hydraulic mSvkh u.ska l%shdlrk Fan j¾.¡

mß.kl u.ska md,kh jk Fan yd isis,k l%u¡

Cooling fan mßlaId lsßfïos th belt u.ska l%shd flfrkï belt fydoska

mßlaId lr ne,sh hq;=h¡ tfukau kshñ; tkacsfï kshñ; WIaKd;ajh

mj;aje.eksug fan tfla l%shdldß;ajho mßlaId lr ne,sh hq;=h¡ tfukau

fan tl lerflk osYdjo ne,sh hq;=h tioyd jdykh mk.kajd bosßfhka

fros lene,a,la we,a j úg we;=,g wefokï th kshñ; osYdjg lrlefõ¡

14

Lubrication system mßlaId lsßu¡

Oil level tl kshñ; uÜgfï we;soehs mßlaId lr ne,sh hq;=h¡ tfukau

Oil j, ;;ajh yd Oil fhdod fldmuk ÿr m%udkhla odjkh lr we;soehs ne,sh

hq;=h¡ Oil leak we;oehso mßlaIdlr ne,sh hq;=h tioyd tkacsfï ndyssßka ldkaÿ

ú we;soehso úYd, f,i Oil wvqúula we;soehso ne,sh hq;=h¡ jdykh mk.kajd

Oil pressure gauge tlla fhdod.ksñka Oil j, pressure tl ksIamdolh os we;s

w.hg we;s oehso mßlaIdlr ne,sh hq;=h¡

15

Fuel system mßlaId lsßu

Fuel filter mßlaId lsßu

fmÜgr,a j, we;s wmøjh fmrd msßisÿ lr.eksug fmÜgr,a filter tlla

fhdod we;¡ gexlsfha isg fmg%,a fmdïmh olajd /f.k tk u¾.fha fuu filter

tl iúlr we;¡

WmlrKqfha we;=<; paper element tlla u.ska fmg%,a j, we;s ishqï

wmøjH rojd ;ndf.k msßisÿ fmg%,a fmdïmh fj; tjkq ,nhs¡ fmg%,a j, c,h

we;akï tho fuu filter u.ska tys hg fldgfia ;ekam;a lsßu isÿfõ¡

merKs jdyk j, fhdod.;a fmg%,a filter .,jd msßisÿ lsßula isÿl, yels

jqjo j¾:udkfha nú;d jd ieu fmg%,a filter tllau tys wdhqld,h wjika

úfuka iïmQ¾kfhkau udrel, hq;=fõ¡ idukaHfhka fuu filter udrel, hq;af;a

2000Km jrls¡

16

Fuel leak mßlaId lsßu

bkaOk gexlsh yd bkaOk gexlsfha isg Carburetor olajd bkaOk f.khk

ud¾. j,g ydks isÿú we;so yd ldkaÿúï we;so hkak mßlaIdlr ne,sh hq;=fõ¡

EFI kï Pressure gauge tlla iïnkao fldg Pressure tl mßlaIdlr ne,sh

hq;=fõ¡

Fuel lines mßlaId lsßu

kdùk Carburetor iys; fudag¾ r:hl bkaOk k, 3la fhdod we; bka 2la

fmg%,a fmdïmhg bkaOk iemhsï yd tys Return line tl fõ¡ b;sß k,h bkaOk

gexlsfha we;sjk fmg%,a jdIamh Charcoal canister tl fj; f.khk ud¾.hhs¡

fuu bkaOk k, r:fha háme;af;ka iúlr we;s w;r b;d wdrlaIdldß

jk mßos wdj¾khkao fhdod we;¡ fuu k, ud¾.j,g ydks isÿú we;so hkak

mßlaId lr ne,sh hq;=h¡ tfia ydks isÿú we;skï w¨;ska fuu k, fhosh hq;=

fõ¡

17

Electrical system mßlaId lsßu

Barrery lkq j,g iïnkao fldg we;s fldgia msßisÿ l< hq;=fõ bkamiq

fydoska iúl< hq;=h¡ Hugh tenstion line j,g ydks isÿúo hkako ne,sh hq;=fõ¡

negß j, wï, ;;ajh yd kv;a;= isÿlrk negßhlakï negß j;=r m%udkho

mßlaIdl< hq;= fõ¡

18

Tune up lsßu

1. Ignition cut lsßu

2. Distributor tflys Plugs wire .e,ùu

3. Distributor tl .,jd bj;a lsßu

4. Contact barker point isreudre lsßu fyd w¨;ska fhosu

5. Capacitor tl mßlaId lsßu

6. High tension wire j, m%;sfrdaOh mßlaId lsßu

7. Plugs ish,a, .,jd Carbon plug kï uqÿk (Tip) msßisÿ fldg tjdfha Gap ksIamdos;hdf.a w.hka wkqj ieliSu (Carbon plug kï 20000km miqj

w¨;ska fhosh hq;=fõ Platinum plug kï 80000km miqj w¨;ska fhosh

hq;=fõ)

19

8. Timing casing tl .e,úu

9. m,uq is,skavrh Compression TDC wjia:djg f.k tu ksIamdol i,l=Kq

j,g wkqj

10. Timing casing tl iúlsßu

11. Distributor tfl ù,a tfla we;s i,l=K iu. Distributor tfl nfoa we;s

i,l=K iu. iumd; lsßu

12. Distributor tl uola iúlr Coil tl;a Distributor tl;a w;rg Test blub tlla iúlsßu

13. Ignition on lsßu

14. Distributor tl lrljd blub tl m;a;= ú ksfuk ia:dkhg ;nd kÜ

;olsßu

15. Ignition off lsßu

16. Plug Ingestion wire ish,a, ksjerosj iúlßu Firing order tlg wkqj

20

17. m,uq msiagkhg tk Ingestion wire tlg Tune up tester tlg iïnkaO

fldg Tune up tester tlg negßfhaka úÿ,sg ,ndos Distributor solenoid tlg Tune up tester tlys Rpm wire iïnkaO lsßu

18. Timing torch tl Ndú;d lr BTDC 5° ksjerosj ;sfnoehs mßlaIdlr

ne,su

19. Vacuum gauge tfla we;s hose 2 manifold vacuum iy ported vacuum tlg iíkao lsßu

20. ksIamdolhd os we;s Rpm w.hg (700rpm) manifold vacuum tl Wmßu

jkf,i Speed adjusting screw (SAS) tl iy Mixture adjusting screw (MAS) lrljd iqir l,hq;=h¡

21

EFI

ENGINE

22

EFI ENGINE

EFI Engine ld,h;a iu. my; f,i ;dlaIKh ossjqkq úh¡

Jetronic

K KE KA L LH D Mono Motronic GDI

Jetronic j,os Electronic j,ska Fuel muks m,kh lrkq ,enqfõ¡ kuq;a

Motronic j,os Electronic j,ska Fuel iy Ignition folu m,kh flf¾¡

Motronic j¾. lsysmhla we;¡

HE Motronic L Motronic LH Motronic

Motronic

23

nú;djk Sensor j¾.

Air flow sensor

Vehicle speed sensor

Temperature sensor

T.P.S (Throttle Position Sensor)

O2 sensor (Lambda)

Knock sensor

Cranks sensor/Cam sensor

A/C switch

Ignition switch

Battery

24

Air flow sensor

fuu sensor tl u.ska tkacsug weo.kakd jd; m%udKh iy Temperature tl

uk.ks¡

Vehicle speed sensor

fuu sensor tl u.ska jdykfha fõ.h .ks th ,nd.kafka .sh¾ fmÜáfhka

fyd ABS ù,a speed sensor tl u.sks¡

Temperature sensor

fuu.ska tkacsfï WIaK;ajh uek.kS¡ fuh tkacsfï Coolant line tfla iúfldg

we;¡A/C cut off lrkafka fuu sensor tl u.sks¡

25

T.P.S (Throttle Position Sensor)

Throttle body ;=, fuh msysgqjd we;¡ fuu.ska Throttle tl msysá ia:dkh

Signal tl .ks¡ Idler ;srkh lrkafka fuu.skah

O2 sensor (Lambda)

Lambda sensor tl u.ska Exhaust manifold tflka msgjk Tlaiscka m%udKh

n,hs¡ bkamiqj Injector u.ska úosk f;,a m%udKh jeä lrhs¡

Knock sensor

Knock sensor tl u.ska tkacsfï Knock n,hs (.eiaisï,fooßï) fuu .eiaisï

yd fooßï we;súug Ignition timing Advents Rita dad úu n,mdhs¡ fuu sensor

tl u.ska Advents Rita dad úu hï mrdihl Auto ilihs¡ th úYd, mrihla

kï tfia ielish fkdyel¡

26

Cranks sensor/Cam sensor

fuu.ska msiagkh msysá ia:dkh,jE,a msysá ia:dkh yd Rpm tl ,nd.ks¡

A/C switch

Idler up lsßu isÿlrhs¡

Ignition switch

tkacsu mk.ekaúug iqokï nj okajhs¡

27

Battery

fuu.ska Battery ;=, mj;sk Odrdj n,;s¡ Odrdj wvqkï Idler up lr pd¾c fõo

n,hs tfi fkdfõkï ;j;a 50rpm fyd hï .kklska Idler up lrhs¡ fufia

100rpm Wmßuhla jk f,i isÿlrhs¡

ECU

ECU tfla Rom yd Ram hkqfõka u;l 2la we;¡ Rom u;lh iaÓr u;lhla

fjhs th ksIamdolh úiska we;=,;a fldg we;¡ Ram u;lh ;djld,sl u;lhla

fjhs¡ jdykfha fodaIhla we;skï fuu Ram u;lfha ;ekam;a fjhs tu fodaIh

ksjeros fkdlg wjqreÿ lsysmhla ;snqfkdfyd;a th;a Rom u;lhg tl;=fõ¡

tfia jqjfyd;a kej; Rom tlys o;a; w¨;ska we;=,;a l< hq;=h¡

28

Fuel injection control

29

Fuel pump control

Idle up control

30

Tune up lsßu

1) Throttle body tl msßisÿ lsßu (fmg%,a fyd Carburetor cleaner u.ska)

2) Injector .,jd msßisÿ lsßu

o EFI tkacska Tune up lsßulos by; oe mukls w;ska l< yelafla Ignition timing jeks oe Scanner tllg jdykh iïnkao lsßfuka lr.; hq;=h¡

31

Injector msßisÿ lsßu

Injector .,jd tys Rings .e,úh hq;=h¡

Carburetor cleaner iaj,amhla oud msg; msßisÿ lr.; hq;=h¡

Ultra sonic washing unit tlg oud nd¾ 3la muk os l%shd;aul lsßu¡

Injector test massing tlg iúfldg tys l%shdldß;ajh ne,sh hq;=h¡

Injector lsysmhla tljr n,kafkakï tys idukH l%shdldß;ajh ne,sh

hq;=h¡ Presser tl nd¾ 3la muk osh hq;=h¡ Injector tl wefrk jefyk

fõ.h fuu.ska ne,shyel¡

32

Scan lsßu

fudg¾ r:hla Scan lsßug wjiah jkafka vEia fndaâ tfla hï fodAIhla we;s

nj fmkakqjqfyd;a fyd tkacska Tune up tllosh¡

Scanner tl iïnkao lrk ksjeros fidlÜ tl jdykfhka fidhd.eksu

Scanner tl jdykhg iïnkao lsßu¡ iuyr Scanner j,g fjku úÿ,sh

iemhqh hq;=h¡

¡Ignition on lr ;eìh hq;=h¡

bkamiq jykfha ksIamdolhd iy r:fha fudv,h Scanner tl ;=,ska f;dard tu

o;a; wkqj lghq;= lsßu¡

fuysos fmkajk fodaIh ksjeros lsßug fmr lsysm jrla Erase lr ne,sh hq;=h¡

ke;skï Erase fkdl, ksjeros l< fodaIhla úh yels ksidh¡ ksjeros l<

fodaIhla kï th Erase fõ¡ Erase fkdfjkï fodaIhla ;sfí th ksjeros l<

h;=h¡

Scanner tl u.ska Injector, Ignition, Petrol pump, j, fodaI mßlaId l< yel¡