ENGINE DISASSEMBLING AND REASSEMBLING
The Need for disassembling an engine
As the engine operate for along period of time the component part of the engine starts to
deteriorate (worn) which results in poor engine performance characteristics.
As result the engine has to be serviced.
ENGINE SERVICEING
Is a method of keeping the engine in a state of safety, reliability performance etc… this also increase the
engine life. In order to restore the normal operating condition the engine has to be maintained
periodically. This type of engine maintenance is called SCHEDULED MAINTENANCE. This can be time based
or mileage based.
BASIC REQUIRMENTS OF ENGINE SERVICING
I. To diagnose (find out) the trouble with an engine.
II. To determine exactly the type of trouble and
III. To determine exactly the trouble with an engine service required to restore to the normal
operating condition.
ENGINE REMOVAL FROM A VEHICLE PROCEDURE
1. Mark hinge location at hood panel for alignment during installation. Remove hood from hinges
2. Disconnect or remove the battery
3. Remove air cleaner assembly
4. Drain the coolant from the cooling system and disconnect the lower and upper hose
5. Drain the oil
6. Remove oil filter
7. Remove radiator and the cooling fan
8. Disconnect electrical wires to starter motor, alternator, oil pressure gauge etc…
9. Disconnect the fuel line
10. Disconnect the exhaust pipe
11. Disconnect the accelerator linkage of engine
12. Support the transmission with a floor jack
13. Support the weight at the engine a lifting device
14. Remove the engine by loosening the retaining nut
15. Remove the engine by pulling forward and upward
CYLINDER HEAD
Material
1. CAST IRON – water cooled diesel truck engine
CUST IRON ADV.
Good bearing surface
Valve seat can be mode in parent metal
Wear resistance
Smaller clearance can be use
CAST IRON DISADV.
Low heat dissipation characteristics
Difficult to machine
Is heaver in weight
DEPARTMENT OF AUTOMOTIVE Page 1
2. ALUMINUM
ALUMINUM ADVANTAGE
Lighter in weight
Good thermal conductivity
Easy machining passable
ALUMINUM DISADVANTAGE
Poor bearing material
Separate valve seat and guides are melt
Greater clearance require due to high thermal expansion
SERVICING CYLINDER HEAD
Removing the head
Check for oil or gas leaks around the base of the head at the gasket line.
Drain coolant from engine before removing the head.
Steam clean the engine to prevent dirt from getting on the internal parts
Inspecting the head
Engines with I-head valves have an oil gallery leading from the bottom to the top of the engine block to
carry oil to the rocker arms. When removing the old head gasket check for leaks around the area.
Replace the gasket to correct the leak
Check for damage to the sealing surfaces of the head or cylinder block. Clean all carbon deposits from the
head by scraping or brushing with a wire brush.
CHECKING HEAD FOR WARPAGE
After long operation the head may contour to match the block this is normal. However, If the engine has
overheated or had compression leaks, the extra heat may have warped the heat.
Check the machined surface of the head for warp age as follows.
1. Clean all the machined surface of the head
2. Use a heavy accurate straightedge and feeler gauge to check for warp age at each end and be
twine all cylinders. Also check for end to end warp age in at least six places.
VALVES
The engine must take in fuel air and exhaust spent gases at precise intervals. The valves do this job by
opening and closing the intake and exhaust ports to the cylinder.
TYPES OF VALVE :- TULIP VALVE AND
FLAT TOP VALVE
Valves are usually constructed from one or two pieces of special alloy steel –CHROMENICKEL for intake
valves. Ail chrome for exhaust valves. (because of the greater heat).
MAJOR CAUSES OF VALVE FAILURES AREA
Distortion of the valve seat
Deposits on valve
Too little tappet clearance … burned valves
Pre ignition -burned valve
Erosion
Heat fatigue
Breaks
Worn valve guides
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REWORKING OR REPLACING VALVES
When removing valves from the engine place them in a numbered rock or otherwise mark them. This
returns each valve to its own valve guide often servicing.
Special tools are a must when reworking engine valves. Valves can’t be refaced on a shop grinding wheel.
1. CLEANING
Hold each valve trimly against a wire wheel on a bench grinder. Remove all carbon from the head face and
stem. Any carbon left on the stem will affect alignment in the valve reface, polish the valve stems with
steel wool or crocus cloth to remove any scratch marks left by the wire brush.
2. INSPECTION
Use micrometer to measure the clearance of valve stem and guides. If the measurements exceed the
specified clearance replace either the valve or guide or both.
3. TESTING VALVES FOR BREAKS
Test all used valves as follows:-
Hold the valve by its stem head, down, and strike it sharply on end of stem with a hammer. If a fracture
exists, the head will break off.
4. REFACING THE VALVES
Locate the working head of the valve reface at the specified angle with valve head. For quicker seating an
interference angle is normally used.
SERVICE VALVE SEATS
1. Cleaning valve seats
2. Cleaning valve guides
3. Measuring valve seat inserts
4. Servicing valve seats
SERVICING VALVE SPRING
Valve spring are tested for proper
1. Tension and
2. Squerness
1. Spring tension is tested by a special fixture
-The pressure required to compress the spring to the particular length is measured in this test.
-Excessive soft are stiff springs are discarded.
2. To test for squerness. Stand the spring with closed coil end down on a flat surface
-Hold a steel square next to it
-Now rotate the spring slowly and observe that the top turn of the coil should not move away from the
square more than 1.5mm.
-The excessively out of square springs are replaced.
CAM SHAFT
Material made of:-
Hard noble cast iron
Steel
Properties:- on gear is provided to drive
Oil pump shaft
Fuel pump and
Distributer shaft
DEPARTMENT OF AUTOMOTIVE Page 3
All are drive by
Belt
Chain and
Gear
SERVICING CAM SHAFTS
Always check the camshaft when you recondition the engine
Inspection of bearing journals and bore
Inspect camshaft journals for signs of wear or out of round condition
Measure the camshaft journals with an outside micrometer
Measure the camshaft bores or bearings with an inside micrometer (or telescoping gauge and
outside micrometer.)
CHEKING CAM LOBES
Using a micrometer, check the height of each cam lobe. Compare intakes to other intakes, and
exhaust cams to their counter parts.
Regrinding and polishing the cams is not satisfactory on modern high speed engines.
Measuring valve lift can give an indication of wear on cam lobes, cam followers and push rods.
SELECTING BEARINGS
Select the proper bearing to match the camshaft journals. Some manufacturers have undersized bearings
for replacement parts as well as special installation tools.
CAM FOLLOWERS
Cam followers work off the lobes of the camshaft and drive the push rods to operate the valves.
NOTE:- cam followers may also be called “VALVE TAPPETS”
CYLINDER BLOCKS
The cylinder block is the main support for the other basic engine parts. The block is usually a one place
casting made gray cast iron.
SERVICING CYLINDER BLOCKS
Strip the cylinder block as outlined in the engine technical manual. After stripping inspect the
block for damage. If the block is still serviceable. Scrape all gasket material from the block. Then remove
all oil gallery plugs and core hole plugs to allow the cleaning solution to contact the inside of the oil and
water passages.
CYLINDERS
The cylinder is basically a hollow tube in which the piston works. There are two basic types of
cylinder:-
Cast in-block
Individual casting (liners or sleeves)
CAST IN-BLOCK:- Automotive engines generally feature the “in block” design. The cylinders are cast in to
the cylinder block so that the cylinders and block form a single unit.
INDIVIDUAL CYLINDER CASTINGS:- The chief advantage of individual castings is that replacement is less
expensive. In high speed engines those individual castings are called LINERS OR SLEEVES.
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TYPES OF LINERS
Dry liners:- are sleeves which fit inside an already completed cylinder. This liner is simply a wearing
surface for the piston.
Wet liners:- form not only the cylinder wall but also the inside of the water jacket.
MEASURING CYLINDERS FOR TAPER AND OUT OF ROUNDNESS
Measuring cylinder bore as follows:-
1. Measuring the bore parallel to the crankshaft at the top end of the ring travel zone.
2. Measure the bore in the same position at the bottom end of the ring travel zone.
3. Measure the bore at right angles to the crankshaft at the top end of the ring travel zone.
4. Measure the bore in the same position at the bottom end of the ring travel zone.
Compare the measurements (1) and (2) to find the out of round wear at the top end of the
bore.
Compare the measurements (2) and (4) to find the out of round wear at the bottom end of the
bore.
PISTON
Parts of piston
Head
Skirt
Land
Oil grove
MATERIAL:- Aluminum alley, Cast iron
CHECKING PISTONS
Basic check
Cleaning
Ring grove wear
Warn piston skirt
Crack on skirt of a round (piston bores)
Piston pin clearance
PISTON PIN
The purpose of piston pin is connect piston with connecting rod.
CHECK PISTON PIN FOR
Out of roundness
Looseness
Check bore for bell mouthing
PISTON RINGS
There are two types of piston ring.
Compression ring
Oil control ring
PISTON CLERANCE
Piston clearance (S) is the difference b/n the minimum cylinder diameter (Dcyl. Min.) and the
maximum piston diameter (D.p.max)
S=Dcyl. Min – dp max
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EQUPMENTS OF PISTON RINGS
Good friction characteristics
High flexibility
Simple to manufacturing
Low cost
INSTALLING PISTON RINGS
Check end gap with filer gauge at the lower area of the worn cylinder.
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