IC ENGINE REBUILDING
AND
RECONDITIONING REPORT
ASSIGMENT OF REASEACH METEDOLOGY
SUBMITTED TO Mr,Dani'el
BY NAME ID/NO
1.Hailu Tadesse...................................ATTC/126/21.
AUTOMOTIVE TECHNOLOGY DEPARTEMENT OF
AGRO-TECHNICAL AND TECHNOLOGY COLLAGE(ATTC)
MESCHEN FUR MESCHEN HARAR, ETHIOPIA.
May 21/4/2023.
1.1.1Measuring tools…………………..
1.1Inspection of Valve and Their Accessories …
1.1.1Valve……………………………….
1.1.1Valve Spring………………….
1.1.3Valve Seat……………
1.1.4Valve Guide…………
1.3Inspection of Rocker Assemblies……………
1.4Valv Lifter and Push Rood…………
1.5Cylinder Head Flatten……………………………
1.6Cylinder Head Bolts ……………………………
LIST OF TABLE
1.1 INPECTION OF VALVE…………………………………..
1.2 Check the valve overall length……………………
1.3 Inspection of cam lobe height …………………..
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Unit 1 Cylinder Head Inspection
1.1 Introduction
Automotive Measuring Instruments/Tools
Measuring tools are precise and delicate instruments. In fact, the more precise they are, the more
delicate they are. They should be handled with great care. Never pry, strike, drop, or force these
instruments. They may be permanently damaged.
accurate measurements very important. Even the slightest error in measurement can be critical to
the durability and operation of an engine and other systems.
Vernier Calliper
A vernier calliper is a measuring tool that can make inside, outside, or depth measurements.
Dial Calliper
The dial calliper is an easier-to-use version of the vernier calliper. Imperial callipers commonly
measure dimensions from 0 to 6 inches (0 to 150 mm).
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Micrometers
The micrometer is used to measure linear outside and inside dimensions. Both outside and inside
micrometers are calibrated and read in the same manner.
Feeler Gauge
A feeler gauge can be used by itself to measure piston ring side clearance, piston ring end gap,
connecting rod side clearance, crankshaft end play, and other distances.
Straightedge
Any surface that should be flat can be checked with a straightedge and feeler gauge set.
Dial Indicator
Dial indicators are available with various face markings and measurement ranges to
accommodate many measuring tasks
CLEANING ENGINE PARTS
Cleaning engine parts is one of the most basic procedures that your machine shop will do, yet it
is also one of the most important parts of the engine repair procedure. Before you can really
inspect the parts for your engine to determine what will need to be done to them, they have to be
cleaned. If the parts aren’t clean, it’s hard to measure them and inspect them for defects etc.
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There are several methods that are generally used to clean parts in a modern Automotive THE
SPRAY WASHER
HOT TANK
THERMAL CLEANING and STEEL SHOT BLASTING
Cylinder Head Component Disassemble
Leave your engine for now and get your cylinder head off the shelf.
Clean your cylinder heads and gasket surfaces
Using the valve spring compressor, remove the valve keepers and valve springs.
Make sure you number all your valves because they must be reinstalled into the same
valve guides.
When all the valves have been removed clean all the carbon deposits off of them with the
wire wheel.
Inspect all the valves for wear and burning.
If possible, clean the intake and exhaust ports with a polishing wheel.
Install the valves in the correct guides and with the use of valve grinding compound,
clean the face to seat surfaces.
When all the cylinder head parts are clean and inspected it is time to reassemble.
Reverse the process and install the valves with the valve spring compressor.
INPECTION OF VALVE
Check the head margin thickness
Standard margin thickness Minimum margin thickness
Intake valve:-1.4mm(0.055inch) Intake valve:- 0.9mm(0.035inch)
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Exhaust valve:-1.8mm(0.071inch) Exhaust valve:-1.3mm(0.051inch)
Measured Value
Number of valve Intake valve Exhaust valve
1 2.00mm 1.4mm
2 0.45mm 1.4mm
3 0.4mm 1.1mm
4 1.35mm 1.1mm
Conclusion: -since all the measured values are below the margin thickness or less than
margin thickness. Therefore, all the valves are must be replaced.
Check the valve overall length
Standard overall length Minimum overall length
Intake valve:-120.4mm(4.752inch) Intake valve:-120.3mm(4.732inch)
Exhaust valve:-120.6mm(4.748inch) Exhaust valve:-120.1mm(4.728inch)
Measured value
Number of valve Intake valve Exhaust valve
1 103.4mm 103.30mm
2 103.25mm 103.25mm
3 103.25mm 103.35mm
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Conclusion:-from this in specification we conclude that all the intake and exhaust valves have
less measured values than minimum overall length. Therefore, those all valves are must be
replaced
Inspection of valve steam diameter
It is measured by micro meter standard values For intake valve 7.975-7.99m
Conclusion:-cylinder number one steam diameter is approximately equal to the standard
values. Therefore all valves can use for the second time.
Inspect valve guide
Standard bushing inside diameter is for 3L is
8.030mm
By using a caliper gauge measure the inside diameter of the valve guide bushing of cylinder number
one of the engine. Steam oil clearance
It is the subtract value of valve steam diameter measurement from the bushing inside diameter
measurement
valve spring.
Inspect valve spring
Squareness of valve spring
By using a steel square, check the squareness of the
Inspection of journal diameter of camshaft
By using micrometer we measure the value of camshaft journal
Standard camshaft journal diameter for NO 1 34.969-34.985mm
For others 27.969-27.985 mm
Inspection of camshaft runs out
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By using dial indicator measure the run out of camshaft.
Standard value 0.1mm
Our measured value of run out at the center is 0.03mm
Conclusion:-our measured vale is less than from the standard value so we can use it.
Inspection of cam lobe height
Standard value for intake lobe is 54.29mm up to 54.31mm.
Standard value for exhaust lobe is 54.99mm up to 55.01mm.
Cam lobe number Intake lobe Exhaust lobe
1 54.27mm 54.89mm
2 54.26mm 54.92mm
3 54.22mm 54.98mm
4 54.28mm 54.95mm
From the above table measured value of cam lobe we should take smallest value from both
intake and exhaust cam lobe respectively.
So that from intake cam lobe we have the smallest value is 54.22mm for cylinder third and from
exhaust cam lobe the smallest value is 54.92mm.
Conclusion:- all our measurement value found in standard value or which is in specification
so this means both the intake and exhaust cam lobe within specification. Therefore, our cam lob
is reused or it is function able.
Specification valve lifter and lifter bore
Standard value of oil clearance is 0.058mm up to 0.088mm. Maximum oil clearance is 0.10mm.
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