TECHNICAL, VOCATIONAL, &TRAINING INSTITUTE (TVTI)

ADAMA POLYTECHNIC COLLEGE SATELLITE PROGRAM

Faculty of Mechanical Technology
Department of Automotive Technology
Program study :- 4th Year Automotive Technology Weekend/Extension Students

Course Name/Title Engine Disassembling, Rebuilding and Testing

Semester: I
Set by :-Mohammed Kedu (M.SC)
Course Outline
This course describes the process in performing corrective maintenance of an internal combustion engine. Engine breakdown
must be restored to its original state as prescribe in the service manual. This course covers engine overhauling. Laboratory
works on Engine removal from a vehicle; Engine disassembling; Engine components testing and measuring; Nature of wear
on engine parts, Engine Assembling; Engine installation on the vehicle, testing engine for operation. Occupational Health and
Safety.
Set by Mohammed K. 1
 Course Content:
1. Introduction 5. Crank gear mechanism (Function,
1.Mechanisms and systems of a reciprocating Component parts, Operation)
IC engines 1.Disassembling of Cylinder block,
2.Principle of engine operation Crankshaft,…
1.Gasoline engine 2.Inspection and repair
2.Diesel engine 6. Nature of wear on engine parts
2. Engine servicing 1.Mechanics of IC engines
2.1. Steps in servicing an engine 7. Assembling the engine
3. Engine removal from a vehicle 1.Assembling of valve gear mechanism
4. Valve gear mechanism (Function, 2.Assembling of crank gear mechanism
Component parts, Operation) 8. Engine installation on the vehicle
1.Disassembling of Cylinder head, Timing 1.Testing engine for operation.
gear (chain or belt), Camshaft,…
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2.Inspection and repair
Evaluation Mechanism:
1. Attendance and assignment – 10%
2. Midterm/ Continuous Assessment – 25%
3. Final/ Continuous Assessment – 35%
4. Practical Assessment – 30%

Reference books:-
1. Engine Repair Manuals ( TOYOTA, NISSAN, … )
2. Gay Lewis Engine service, 1986
3. May, Ed. Automotive mechanics
4. Chisholm, Ian Automotive engine and vehicle technology
Automotive Engines Diagnosis, Repair And Rebuilding,6th Edition,Tim Gilles Santa
Barbara City College Santa Barbara, Ca

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Engine Disassembling, Rebuilding and Testing

Set by Mohammed K. 4
 Engine Disassembling, Rebuilding and Testing
Chapter One
1. Introduction
1.1 Mechanisms and systems of a reciprocating IC engines
1.2 Principle of engine operation
1. 2.1 Gasoline engine
1.2. 2 Diesel engine

Introduction
An Engine is a mechanical machine used to convert the chemical energy of the fuel into heat energy and
then to mechanical energy. It is usually called a Heat Engine.
Basically there are two types of heat engines external and internal combustion engines.
In an external combustion engines combustion (burning of a fuel) is taking place outside of the engine.
Eg. Steam engines
In an internal combustion (IC) engines combustion is taking place within the engine itself. Eg.
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Spark Ignition (SI) engines
Cont’d

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 Engine mechanisms

Crank gear mechanism Valve gear mechanism

• Crank shaft • Camshaft
• Connecting rod • Valve lifter (OHV)
• Piston • Push rod (OHV)
• Cylinder • Rocker arm
• Valve spring
• Valves

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 Engine Classifications
Classification / group Indicator / value
Number of cylinders 1, 2, 3, 4, 5, 6, 8, 12
Arrangement of cylinders inline, V-shaped, opposed and
Round
Type of cooling Air cooled vs. Liquid cooled

Type of fuel used Gasoline vs. Diesel

Operation Cycle 2-stroke vs. 4-stroke
Engine capacity different swept volumes, e.g.
2.5l
Arrangement of valve OHV, OHC,
mechanism Set by Mohammed K. 8
Component parts of a valve-gear-mechanism.

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Fig.1 OHV engine

Set by Mohammed K. 10
 What is the function of a crank gear mechanism?
 The crank gear mechanism of an IC engine consists of those
parts, which convert the chemical energy of fuel into heat
and then to mechanical energy.

Fig. 5.1. The Set

crank gearK. mechanism
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 Operation

 As the air-fuel mixture is burned during the power stroke, the chemical energy of the
fuel is converted into heat energy due to the chemical reaction (combustion) process.
 As a result the temperature and hence the pressure of the mixture tends to increase
sharply.
 This high pressure of burned gas exerts a huge force or load (in Tons ) on the piston
head.
 The piston is then forced to move from TDC to BDC position.
 This piston motion by means of the connecting rod is transferred to the crankshaft and
then to the flywheel as a mechanical energy.

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Engine Operation

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 Characteristics
Because of the construction size consideration and efficiency, automobile uses the internal
combustion engine type. The two most common engine used by automobile manufacturers are
the ‘’ gasoline and diesel engine ‘’.
Gasoline engine
High speed and high power output; easy to operate; quiet combustion; used widely for passenger cars, small
trucks, and uses gasoline fuel only.
Diesel engines
Higher heat efficiency, better fuel efficiency and low speed performance than gasoline engines; heavier than
gasoline engines, low speed engine, higher torque and produces more vibration and noise and uses only diesel
fuel.
Gasoline engines burn gasoline fuel.
The mixture of gasoline and air is ignited inside the cylinder with the spark plug.
Diesel engines burn a light oil called diesel fuel. It does not use spark plug in combustion .
The heat of compression is used in producing heat needed in combustion of diesel fuel and air.
Gasoline and diesel engine are similar in construction.
The main difference between gasoline engine parts and diesel engine parts is that the diesel parts are usually
heavier and stronger. This is because the internal pressures
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K. higher in diesel engines. 14
Number of cycle
Cycle is a continuous repetition of the series of events in an engine
operation. Automobile engines are classified according to the number of
cycle such as
“2-stroke and 4- stroke cycle” engines.

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 The four-stroke gasoline engine cycle of operation
The four-stroke cycle of operation is generally referred to as the “Otto cycle” after Dr Nicolaus A. Otto who
first applied it in practice. A certain series of actions have to be completed to admit the fuel to the engine
cylinder, to compress the mixture of air and fuel, to allow the gases to expand during the power stroke, and
finally to expel the burnt exhaust gas from the cylinder. These various actions constitute what is known as
the “Cycle of operation”.

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 The four-stroke Diesel engine cycle of operation
In the compression ignition (CI) engine the degree of compression is much higher than in the gasoline
engine, so that the heat produced by the compression is sufficient to ignite the fuel without the need for a
spark. The fuel employed in this type of engine is less volatile than gasoline, although of a similar
chemical nature.

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4-stroke gasoline engine strokes
Intake- intake valve opens (theoretical stroke: at TDC)
- exhaust valve is closed (theoretically: since TDC)
- piston moves downward
- distance TDC to BDC = 180° crank angle
- suction occurs / partial vacuum (-0.1 to -0.3 bar)
- air-fuel mixture (14.8 : 1) is drawn into the cylinder
Compression - intake valve closes (theoretical: at BDC)
- exhaust valve still closed
- piston moves upward (BDC  TDC = 180°)
- volume decreases
- air-fuel mixture gets compressed to (1/7 to 1/12)
- air-fuel mixture is heated up (molecular motion)
- increasing heat causes higher pressure (18 bar)
- higher heat improves mixing of the gases

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 Power - both valves are still closed (theoretically: till BDC)
- combustion is initiated by the spark from the spark plug  IGNITION
- time from start of combustion till complete combustion about 1/1000 s!
- delay in flame propagation requires ignition before TDC
- combustion speed up to 20 m/s- highest combustion pressure about 30 - 60
bar at around 4° - 10° a.
- TDC- expansion of hot gases (up to 2500° C) forces the piston from
TDCBDC
- heat energy is transferred into mechanical energy
Exhaust - exhaust valve opens (theoretically: at BDC)
- intake valves remains closed (theoretically: till TDC)
- due to rest pressure from combustion of 3-5 bar exhaust gases leave the
cylinder with sonic sound
- exhaust gas temperature still be around 900° C
- piston moves upward (BDC  TDC = 180°)
- rest of exhaust gases pushed out with around 0.2 bar
Summary: - 4 strokes = 720° crank angle = 360° camshaft angle
- 4 strokes = 2 crankshaft rotations = 1 camshaft rotation
- each theoretical stroke is 180° crank angle
- spark ignition takes place at or before TDC

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 The two-stroke gasoline engine cycle of operation
The conventional three-port two-stroke engine does not employ mechanically operated valves. Instead,
ports are formed in the cylinder walls, which are covered and uncovered by the movement of the piston.
In this type of engine there are only three moving parts: the piston, connecting rod, and crankshaft. The
cycle of operation is completed in two strokes of the piston or one revolution of the crankshaft.

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 The two-stroke Diesel engine cycle of operation
An air chest surrounds the cylinder or box, which is kept charged with air under pressure by an
engine-driven blower. Ports lead from the air chest into the cylinder. Movements of the piston
control the flow of air from the chest into the cylinder. Poppet type exhaust valves are located in
the cylinder head and these are operated by conventional cams, push rods, rocker arms, etc.,
and are closed by springs. As the piston uncovers the ports the incoming air, as well as filling the
cylinder, assists in disposing of the gases past the open exhaust valves at the top of the cylinder.
The cycle of operation of a two-stroke CI engine is described in the following.

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 Mechanisms and systems of a reciprocating IC engines
i. Engine mechanisms,
a) crank gear mechanism:- which includes the crank shaft, connecting rod, piston
and cylinder.
b) valve gear mechanism:- which includes the camshaft, valve lifter, push rod,
rocker arm and shaft, valve spring, intake and exhaust valves.
Engine systems,
 The starting system;- which includes the battery, start/ignition switch, starter motor.
 The intake system:- which includes the air filter, carburetor, intake manifold.

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 Cont’d
 The fuel system:- which includes the fuel tank, fuel line, fuel filter, fuel pump and
carburetor.
 The ignition system:- which includes the battery, start/ignition switch, ballast resistor,
ignition coil, distributor, HT cable and spark plug.
 The lubricating system:- which includes the oil pan, strainer, oil pump, oil line, oil
filter.
 The exhaust system:- which includes the exhaust manifold, exhaust pipe, catalytic
converter, muffler, tail pipe.
 The charging system;- which includes the battery, start/ignition switch, regulator,
alternator.
 The cooling system:- which include the radiator, lower hose, water pump, water
jacket, thermostat, upper hose, cooling fan.

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 Chapter Two
ENGINE SERVICING
Engine servicing is a method of keeping the engine in a state of better performance,
lower fuel consumption and lower emission.

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 Introduction
Before servicing an automobile, it is necessary to determine the cause of
the trouble in the automobile. This is done by observing the symptoms
produced by the trouble and indicated in the instrument checks, visual
examination, sounds. The analysis of troubles and troubleshooting charts
are very helpful for this purpose. In an automobile trouble are liable to
occur in all the systems like fuel. Lubrication, cooling, ignition, breaking as
well as in engine power train.

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Maintenance Definition
• maintenance is a set of organised activities that are carried out in order to keep an item in its best
operational condition with minimum cost acquired.
• Activities of maintenance function could be either repair or replacement activities, which are necessary
for an item to reach its acceptable productivity condition and these activities, should be carried out with a
minimum possible cost.
Scheduled Maintenance
• Scheduled maintenance is a stitch-in-time
procedure and incorporates
– inspection
– lubrication
– repair and overhaul of equipments
• If neglected can result in breakdown
• Generally followed for:
– overhauling of machines
– changing of heavy equipment oils
– cleaning of water and other tanks etc Set by Mohammed K. 26
 Student Learning Objectives
• Identify measuring and testing equipment for internal combustion engines
• Identify the specifications of an internal combustion engine
• Explain four major specifications to be checked on small engines.

Terms
• Compression gage • Plastigage
• Dial indicator
• Round-wire gage
• Flat feeler gage
• Inside micrometer set • Tachometers
• Micrometer caliper • Telescoping gage
• Torque wrench
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 Tools Used in Measuring Engine Components
• Micrometer caliper – precision measuring tool for taking outside measurements.
• Inside micrometer – determines the inside of a cylinder.
• Flat feeler gage – recognizes the spacing between two surfaces.
• Dial indicator – recognizes the spacing between two surfaces and records readings of the dial needle.
• Round-wire gage – used in measuring the electrode gap of spark plugs.
• Plastigage – a thin, plastic, threadlike material used to measure the clearance between the bearing journal
on a crankshaft and the bearing rod cap.
• Torque wrench – the hand tool used for torque which bolts and nuts must be tightened to.
• Compression gage – helps in determining if there is a problem with the cylinder, piston rings, valves, or
gaskets.
– It measures compression pressure in pounds per square foot
• Telescoping gage – a tool used for measuring inside diameter.
• Tachometers – used for reading revolutions per minute.

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 Engine servicing

Engine Tune-up Engine Overhaul

Partial Overhaul Major Overhaul

Engine Engine
Reconditioning
Rebuilding

Engine Engine
Reconditioning
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Rebuilding 29
Types of Servicing

The servicing of a motor vehicle is of following types

1. Cleaning of the motor vehicle and its parts
2. Inspection and repair of different parts
3. Adjustments
4. Greasing and lubrications

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As the engine is operating for a long period of time some component parts start to
deteriorate. As a result the engine starts to loose its performance.
In order to restore almost to its original operating condition the engine has to be
maintained periodically. This type of maintenance is called scheduled
maintenance. Scheduled maintenance can be time based or mileage based.
In other cases the engine may fail unexpectedly, in this case the type of servicing or
maintenance required is called unscheduled maintenance.
The major steps in servicing an engine are to:
diagnose (find out) what is wrong within an engine.
determine exactly the type of troubles.
determine exactly the type of service required
to restore to the normal operating condition.
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Diagnosing engine troubles is a method of finding out the troubles within the
engine by visual examination, by the sound produced, by the smoke of the exhaust and
with the help of instruments.
Types of engine troubles:
 external trouble
 internal trouble
External troubles: the engine exterior should be thoroughly inspected and the defective
parts have to be adjusted. This type of servicing is called an engine tune-up.

Internal trouble: a case that requires disassembling the engine to identify the causes of
the trouble. The trouble may be of burnt valves, worn out cylinder walls, broken piston
rings, defective bearings, etc. This requires further exhaustive servicing, and this type of
servicing is called an engine overhaul.

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Engine tune-up is the process of checking and adjusting different components of an engine, such
as: carburetor, spark plugs, contact breaker point, belts, ignition timing, etc. to obtain the
maximum performance.

Engine overhaul is of two types; partial (top) overhaul and major overhaul. Partial (top) overhaul
includes; removing and cleaning of carbon from the cylinder head, valves, pistons; lapping and
rubbing with abrasive; valves, valve seats, repair and replacement of minor assemblies as cylinder
head gaskets. In this case there is no need of removing the engine from the vehicle. Major
overhaul is includes; the partial (top) overhaul; removal of pistons, piston rings, connecting rods,
crankshaft bearings, checking, repair and replacing of worn out parts. In this case the engine has
to be removed from the vehicle.

Engine reconditioning: During an engine overhaul some parts may worn but may
remain within their service limits. In such cases the parts have to be repaired. This
process is called engine parts reconditioning.
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Engine rebuilding:- During an engine overhaul some parts may wear beyond their
service limits. In which case the parts have to be replaced. This process is called
engine rebuilding.

Types of Maintenance
There are four types of vehicle maintenance namely
1. Preventive maintenance
2. Brake maintenance
3. Periodic maintenance (or) schedule maintenance
4. Operation maintenance
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 1. Preventive maintenance :
Prevention without breakdown or without
giving trouble on road some attention or maintenance taken to the vehicle is called as
preventive maintenance.
It intends to reduce or totally eliminate breakdowns and accidents due to mechanical
failures and reduces repair cost.
Any good preventive maintenance program leads to following advantages.
(a) Reduce the breakdown of vehicle
(b) Increased safety due to reduced breakdown
(c) Less expenses on repairs
(d) Good control on inventory of spare parts
(e) Lesser number of equipments are required

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 2. Break down maintenance :
Break down maintenance is the attention which is to be provided when a motor vehicle
becomes immobilized due to faults created during running.
These faults are started difficulties, puncture ,electrical faults, carburetors and fuel supply
faults, overheating, fan beltings breakage and accidents etc.

3. Periodic maintenance :
Periodic maintenance or operative maintenance is the attention provided to motor vehicle
after in operation for a specified time or covered distance. These maintenance may be done
daily ,weekly, quarterly, yearly or after covering every 500km, 1000km, 2000km, 4000km,
8000km, of running.
In garages this work is done on the basis of preset schedules so as to avoid road failures and
to minimize break down during use. Set by Mohammed K. 36
 4. Operation maintenance :
Daily maintenance by the operator for proper running of the vehicle
is known as operation maintenance.
It is needed to keep the vehicle in proper working condition.
Tire inflation, battery, brakes, clutch, smoke color, starting system,
ignition system and lights are checked in this maintenance daily.

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 Chapter-3
Common Engine Removal Procedure

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 Engine removal from the vehicle as summary
1. Mark hinge locations 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 cooling system and disconnect the lower and upper hoses.
5. If equipped with automatic transmission disconnect cooler lines from
radiator.
6. Drain the oil.
7. Remove oil filter.
8. Remove radiator and radiator fan.
9. If equipped, remove power steering pump and drive belt from the engine.
10. Disconnect electrical wires from starter motor, ignition coil, alternator,
oil temperature and pressure gauges etc.
11. Disconnect fuel lines.
12. Disconnect exhaust pipe.
13. Disconnect accelerator linkage at engine.
14. Support transmission with a floor jack.
15. Support the weight of the engine with a lifting device.
16. Remove engine support cushion frame retaining nuts.
17. Remove engine by pulling forward and upward. Set by Mohammed K. 39
Disconnect or remove parts

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 ENGINE REMOVAL PROCEDURES

The general procedures to follow for engine removal are similar in most cases. For special conditions and procedures, the
manufacturer’s service manual should be consulted.
1. Use fender covers.
2. Scribe a mark around the hood hinges for reference when reinstalling hood.
3. Remove the hood attaching bolts and have an assistant help you with removal. Avoid damage to the car finish. Be
especially careful when handling aluminum hoods.
4. Remove the storage battery. Identify the battery and store it properly to avoid damage.
5. Drain the engine coolant from the radiator and engine block. Save the coolant if it is to be used again; usually, it is
replaced because of contamination and deterioration.
6. Remove the radiator, shroud, and fan. Disconnect the transmission oil cooler lines first, if so equipped, and prevent fluid
drainage from lines. If the vehicle is equipped with air conditioning, do not .disconnect the AC condenser lines.
7. Remove the air cleaner and emission-control lines. Identify the lines with masking tape to aid in assembly.
8. Disconnect all electrical connections attached to the engine assembly. Identify with tape if needed.
8. If the vehicle is equipped with air conditioning, do not disconnect the AC compressor lines. Remove the compressor and
place it in the engine compartment so that it is out of the way for engine removal.
10. Do not disconnect the power steering lines. Remove the power steering pump and store in the same manner as the AC
compressor. Set by Mohammed K. 41
 11. Remove any other engine accessories that may interfere with engine removal (carburettor, fuel rack, starter, alternator,
exhaust). Be sure to cap all diesel fuel lines to prevent entry of dirt.
12. Raise the vehicle and place on safety jack stands just high enough to permit access under the vehicle. (If raised too high,
a floor-type engine lift may not be able to raise engine high enough to clear the engine compartment.)
13. Attach engine lift brackets to the engine; attach one at the front and one at the rear. Use bolts of sufficient diameter and
length to carry the engine weight. Bolts used must tighten lift brackets firmly to the engine. Connect the lift and apply some
tension.
14. Remove the exhaust pipe to manifold bolts if not done previously.
15. Drain the engine oil.
16. (a) If the transmission is to be left in the vehicle, it should be supported in its normal operating position. Be careful not to
dent the automatic-
transmission oil pan. Remove the converter drive plate bolts since the converter must stay with the transmission to prevent
front seal damage and fluid loss. Remove the bell housing attaching bolts.
(b) If the transmission is to be removed with the engine, drain the transmission. Disconnect the transmission rear mount.
Remove the drive line (tape U joints to cross). Disconnect the speedometer cable, vacuum and electrical connections, and
control linkages. Remove the cross member if necessary.
(c) On front-wheel-drive engines, the engine and transaxle are sometimes removed as an assembly. In this case, the drive axles
must be disconnected from the transaxle. 17. Remove the motor-mount attaching bolts.
18. Lift and tilt the engine as required, being careful that the engine does not bind or damage any engine compartment42
Set by Mohammed K.
components during this procedure (Figure-1).
Set by Mohammed K. 43
 Final assembly , installation & start up procedure
Completing the engine assembly includes installing the exhaust & the intake manifolds , carburettor, starter, distributor
,water pump , emission control device ,fuel pump , injectors , glow plugs ,& motor mounts. If the transmission was
removed, after engine removal, it should now be installed . all bolts should tightened to specifications and in the proper
sequence as specified in the shop manual .
Normally all these items should be inspected , cleaned , corrected ,or replaced as needed before installation on a rebuilt
engine.
In general the following procedure should followed;
1. Lower the engine carefully in to the engine compartment with the engine at an angle which is lower at the rear.
2. Carefully guide the engine in to place as it is being lowered at the same level the engine to its normal position.
3. if the engine and transmission are being installed as an assembly carefully raise the rear of the assembly to allow cross
member installation.
4. if the transmissions was left in the vehicle avoid damage to the clutch disc (standard transmission) or flax plate(automatic
transmission )during alignment procedure.
5. connect the transmission to bell housing to the engine and tighten all attaching bolts to the specifications.(automatic
transmission)
6. Connect transmission to the bell housing (standard transmission) and tighten all bolts to the espsification.
7. align and connect the torque converter ; tighten converter drive bolts to spsifications
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 8. Align the motor mounts and tighten the bolts to specifications.
9. Remove the engine lift attachment.
10. Attach the exhaust pipes with new gaskets.
11. Make all electrical, fuel, and emission control connections; attach all linkages and install new oil filter.
12. Install the radiator and hoses.
13. Fill the cooling system with correct antifreeze solution (including reserve tank).
14, Install the specified amount of recommended engine oil, including allowance for oil filter.
15. Install the fully charged battery; make sure all connections are clean and tight.
16. Make sure all connections are properly made and are tight before starting engine.
17. Start the engine and observe the engine oil pressure to be sure the system is operating normally.
18. Set the engine idle speed to approximately 1000 rpm.
19. Observe the oil pressure, coolant temperature indicator, and charge indicator to make sure all systems are operating
properly.
20. While the engine is running, carefully check for any oil or coolant leaks (correct if necessary); the engine should be run
until normal operating temperature is reached.
21. If specified in the shop manual. Re-torque the cylinder heads after engine has reached operating temperature. (If the heads
are re-torquing, the valve ad. justment may have to be corrected.).
22. Install the hood in accordance with the scribe marks made when the hood was removed.
23. Correct the coolant level if required. Set by Mohammed K. 45
 Chapter-4
VALVE GEAR MECHANISM DISASSEMBLING
4.1 Disassembling of Cylinder head, Timing
gear/chain/belt, & Camshaft
Perform the following tasks before disassembling:
inspect the condition of the engine visually.
Set cylinder No. 1 at the end of compression
stroke.
Check the timing marks.
Identify the direction of engine rotation.
Measure the timing gear backlash or timing
chain slack.
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 ENGINE DISASSEMBLING PROCEDURES.
1. Prepare and clean working areas.
2. Prepare the necessary tools and equipments
3. Clean and inspect engine external parts
4. Check the timing marks.
5. Remove cylinder head cover
6. Loosen and remove the cylinder head bolts, starting from the two ends/from outside to the center.
7. Remove the cylinder head
8. Loosen and remove the oil sump bolts and remove oil sump.
9. Check the connecting rod cap position or marks.
10.Loosen and remove cylinder No. 1 connecting rod cap and remove No. 1 position.
11.Use the same procedure to remove #2, #3,#4,#5,& #6 connecting rod and position and put them
according to cylinder number
12.Loosen and remove the main journal caps, bolts and remove crank shaft.
Set by Mohammed K. 47
 Disassemble the parts in the numerical order as shown
1. Head rear plate
2. Fuel pipe and vacuum
hose
3. IN and EX manifold
4. Water outlet
5. Spark plug and tube
6. Cylinder head cover
7. Rocker arm shaft assembly
8. Valve push rod
9. Cylinder head
10. Valve, spring and oil seal Set by Mohammed K. 48
Cylinder heads are the most frequently serviced Disassembling -Cylinder head
engine components; this is due to the
The engine should be cool (room
following rationalities:
temperature) before the cylinder heads
1. The highest temperatures and pressures in are removed.
the entire engine are located in the The head bolts should be loosened from
combustion chamber. the outside and you should work your
2. The valves in the cylinder head(s) must open way toward the center of the head to
and close thousands of times each time the avoid the possibility of warping.
engine is operated.
Combustion chambers of modern automotive
overhead valve engines are of two basic types:
1. Non-turbulent/tube/ hemispherical
chamber and
2. Turbulent wedge chamber.
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Removing the Overhead Camshaft:
The overhead camshaft will have either one-piece bearings in a solid bearing support or
split bearings and a bearing cap.
When one-piece bearings are used, the valve springs wiII have to be compressed with a
fixture or the finger follower will have to be removed before the camshaft can be pulled
out endwise.
When bearing caps are used, they should be loosened alternately so that bending loads are
not placed on either the cam or bearing caps
Removing the rocker arm assembly:
A high-performance racing engine that uses a rocker arm shaft. When disassembling this
style of engine, it is important to loosen the rocker arm shaft bearing caps a little at a
time along the entire length of the shaft to prevent bending.
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Remove the valves from the cylinder head:
Remove the valves from the cylinder head as illustrated below.

Compress the valve spring with a valve spring compressor to

remove the valves.
Keep the push-rods in correct order.
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 Keep valves and springs in correct order.
When disassembling or reassembling a cylinder head,
always wear safety glasses. Valve springs, when
compressed, represent stored energy. Valve keepers can
be sent flying through the air by the force of an expanding
valve spring, which could put out an eye or cause other
physical harm.
Task—1: Adjusting valve clearance

Objective:- At the end of the task the student check & Material:- Life engine
adjust the valve clearance of the engine Equipment:- Wrenches , Filler
Gauge , Screw Driver

Set by Mohammed K. 52
Valve clearance adjustment procedure.
A)Warp up the engine to normal operating temperature.
B)Stop the engine and remove the valve chamber cover.
C)Set No. 1 cylinder to TDC/compression.
 Turn the crankshaft with a wrench to align the timing marks at TDC. Set the groove on the pulley to
O position.
 Check the rocker arms on No.1 cylinder are loose and rockers on No.4 are tight.
 If not, turn the crankshaft one complete revolution and align marks as above.

D) Adjust the clearance of half of the valves.

 Adjust those valves indicated by arrows.
 Valve clearance :- INTAKE--------0.2mm(0.008in)
EXHAUST-------0.3mm(0.012in)
 Use a feeler gauge to measure between the valve steam and the rocker arm.
 Loose the lock nut and turn the adjusting screw to set the proper clearance.
 Hold the adjusting screw in position, and tighten the lock nut.
 Recheck the clearance. The feeler gauge should move with a very slight drag.
Set by Mohammed K. 53
E) Turn the crankshaft one complete revolution
(360˚) and align timing marks in the manner
mentioned above. Adjust only the valves
indicated by arrows.
F) Reinstall the valve cover.

Set by Mohammed K. 54
 Task—2: Remove cylinder head bolts& cylinder head.

Objective:- At the end of the task the Material:- Live engine

student remove the cylinder head Equipment:- Wrenches , Wooden block.
according to the correct procedure.
 Working on top of the engine Remove cylinder head bolts
becomes easy if the hood is  The normal procedure for carrying out only upper-engine service
removed. is to leave the engine in the chassis, and remove the components
 Remove cylinder head bolts required to undergo the servicing.
gradually in two or three passes and  It is advisable to clean the engine exterior and the engine
the numerical order shown. compartment before taking up any job.
Caution: Head war page or cracking  A clean engine is easier to work on, it helps keep dirt out of the
could result from removing in engine,Setand it minimizes
by Mohammed K. accidental damage from slipping tools.
55
 Task—3: REMOVE VALVES
Objective:- At the end of Material:- Cylinder head with valves are
the task the student assembled
remove the valves from Equipment:- Valve spring compressor,
the cylinder head & put Wooden block.
them in order at the
wooden block.
REMOVE VALVES
Using SST, compress the valve retainer until the two keepers can be removed.
 SST 09202-43013
A)Remove the valve keepers, retainers, spring and valves.
B)Remove the valve seals
C)Using a small screw driver or magnet, remove valve spring seats.
 Note: Keep the valves arranged so that can be installed in the same order as removed.
Set by Mohammed K. 56
 Task—4: Clean combustion chamber
Objective:- At the end Material:- Cylinder head with valves
of the task the student are removed.
clean & inspect the Equipment:- Wire brush , Drilling
combustion chamber. machine

Clean combustion chamber

Using a wire brush, remove all the
carbon from the combustion chamber.
Caution: Be careful not to scratch the
head gasket contact surface

Set by Mohammed K. 57
 Task—5: Clean cylinder head
Objective:- At the end of the task the Material:- Cylinder head with valves are
student clean & inspect the cylinder head. removed.
Equipment:- Soft brush , Solvent
Clean cylinder head
Using a soft brush and solvent thoroughly
clean the head

Set by Mohammed K. 58
 Task—6: Inspect cylinder head for flatness

Objective:- At the end of the Material:- Cylinder head with valves are
task the student inspect the removed.
cylinder head for flatness . Equipment:- Straight edge , Filler gauge
 Maximum Inspect cylinder head for flatness
warpage:0.10mm(0.0039in) Using a precision straight edge and thickness
If warpage is greater than gauge, measure the surface contact the
maximum, replace the cylinder block and manifold.
cylinder head.
Set by Mohammed K. 59
 Task—7: Inspect cylinder head for cracks
Objective:- At the end Material:- Cylinder head with valves are
of the task the student removed.
inspect the cylinder Equipment:- Dye penetrate.
head for cracks .

Inspect cylinder head for cracks

 Using a dye penetrate, check the
combustion chamber and exhaust ports,
head surface and the top of the head for
cracks.
 If cracked, replace the head

Set by Mohammed K. 60
 Task—8: Clean Valves
Objective:- At the end of Material:- Removed engine valves
the task the student inspect Equipment:- Wire brush , Scraper.
& clean the engine valves
Clean Valves
1. Using a gasket scraper, chip any carbon from
the valve head.
2. Using a wire brush, thoroughly clean the valves.

Set by Mohammed K. 61
 Most of the time, the intake valve is larger
than the exhaust valve, due to the fact to that
the driving force of the fresh charge to the
engine cylinder is the atmospheric pressure.
On the other hand, there is a pressure left from
the combustion process.
This force is higher enough to expel the
exhaust gases when exhaust valve is opened.

Set by Mohammed K. 62
 Task—9: Inspect valve stem and guide bushings.

Objective:-At the end of Material:- Removed engine valves , Cylinder head with
the task the student the valve guide bushing assembled.
inspect valve steam and Equipment:- Dial gauge , Telescopic gauge , Inside
guide bushings. micrometer , Outside Micrometer.
Inspect valve stem and guide bushings.
A) Using a caliper gauge, measure the inside diameter of
the valve guide bushing.
 Guide inside diameter:-6.010-6.030 mm (0.2366-
0.2374in.)

Set by Mohammed K. 63
 Cont’d
B ). Using a micrometer, measure the diameter of the valve
steam.
Stem diameter
Intake -5.970-5.985mm (0.2350-0.2356in.)
Exhaust- 5.965-5.980mm (0.2348-0.2354in.)
C) . Subtract the valve steam diameter measurement from
the valve guide bushing inside diameter measurement.
Standard stem oil clearance
Intake -0.025-0.060mm (0.0010-0.0024in.)
Exhaust- 0.030-0.065mm (0.0012-0.0026in.)
 If clearance is greater than maximum, replace the valve
guide busing.

Set by Mohammed K. 64
 Cont’d
If necessary, replace valve guide bushing
A)Insert an old valve guide wrapped with tape into the valve
guide bushing and break off the valve guide bushing by
hitting with a hammer.
 Notice: - Be careful not to damage the lifter hole.
B) Gradually heat the cylinder head to
approximately 90˚ C.
C) Using SST and hammer, drive out
valve guide bushing.
 SST 09201-70010
D) Using a caliper gauge, measure the
valve guide bore of the cylinder head.

Set by Mohammed K. 65
 Both intake
& Exhaust Cont’d
Bushing Bore Bushing
in mm(in) size
11.000-11.027 Use STD
(0.4331-0.4341)
Over 11.027 Use O/S E) Select a new valve guide bushing
(0.4341) 0.05 If the valve bushing guide of the cylinder head is more than
11.027mm (0.4341 in.), machine the bore to the following
dimensions
Rebored valve guide bushing bore dimension:
11.050-11.077 mm (0.4350-0.4361 in.)
F) Gradually heat the cylinder head to approximately 90˚
C.(194. ˚ F)
G) Using SST and hammer, drive in a new valve guide
bushing until the ring makes contact with the cylinder head.

H) Using a sharp 6mm (0.24 in.) reamer, ream the valve guide bushing to obtain standard specified
clearance between the valve guide bushing and the newSetvalve.
by Mohammed K. 66
 Task—10: Inspect and grind valves
Objective:-At the end of Material:- Removed engine valves.
the task the student Equipment:- Valve grinder machine.
inspect and grind valves.
Inspect and grind valves
A) Grind the valve only enough to
remove pits and carbon.
B) Check that the valve is ground to the
correct valve face angle.
Valve face angle: 44.5˚

Set by Mohammed K. 67
 C) Check the valve head margin thickness. Cont’d
 Standard margin thickness: 1.3 mm (0.051 in.)
 Minimum margin thickness: 0.5 mm (0.020 in.)
 If the valve head margin thickness is less than minimum, replace the
valve.
D)Check the valve overall length.
 Standard overall length: 98.1 5 mm (3.8642 in.)
 Minimum overall length: 97.75 mm (3.8484 in.)
 If the valve overall length is less than minimum, replace the valve

E) Check the surface of the valve stem tip for wear.

If the valve stem tip is worn, regrind it with grinder or
replace the valve if necessary.
NOTICE: Do not grind off more than minimum overall
length.

Set by Mohammed K. 68
 Task—11: Inspect and clean valve seats
Objective:-At the end of Material:- Cylinder head with valves
the task the student removed
inspect and clean valve Equipment:- Valve seat grinder
seats machine, Prussian blue (or white lead
INSPECT AND CLEAN VALVE SEATS
A) Using a 45˚cutter, resurface the
valve seats. Remove only enough metal
to clean the seats.

Set by Mohammed K. 69
C) Check the valve face and seat for the following: Cont’d
 If blue appears 360° around the face, the valve is concentric.
 If not, replace the valve.
 If blue appears 360° around the valve seat, the guide and seat are concentric.
 If not, resurface the seat.
 Check that the seat contact is on the middle of the valve face with the
following width:- 1.4 mm (0.039 - 0.055 in.)
 If not, correct the valve seat as follows:
 If seating is too high on the valve face use 30° and45' cutters to correct the
seat.

D) Hand-lap the valve and valve

seat with an abrasive compound.
. If seating is too low on the valve face, use 60'
and45' cutters to correct the seat.
Set by Mohammed K. 70
 Task—12: Inspect valve springs
Objective:-At the end Material:- Valve spring
of the task the student Equipment:- Surface plate , Try-square , Filler
inspect valve springs. gauge , Vernier clipper , Spring testing machine .

INSPECT VALVE SPRINGS

A) Using a steel square, measure the square ness of
the valve springs.
 Maximum square ness:- 1.5 mm (0.059 in.)
 If square ness is greater than maximum, replace
the valve spring.
B) Using calipers, measure the free length of the valve spring.
 Free length: 41.64 mm (1.6394 in.)
 If the free length is not within specification, replace the valve spring.
C) Using a spring tester, measure the tension of the valve spring at the
specified installed length.
Installed tension:
 16.0 kg (35 Ib, 157 N) at 35.0 mm (1.378 in.)
 If the installed tension is not as specified, replace the valve spring.
Set by Mohammed K. 71
 Task—13: Inspect camshaft and bearing caps
Objective:-At the end of the Material:- Engine camshaft
task the student inspect Equipment:- Surface plate , Dial-indicator , Vee-
camshaft and bearing caps Block , Vernier clipper , Micrometer .

INSPECT CAMSHAFT AND BEARING CAPS

A) Place the camshaft on V-blocks and, using a dial
gauge, measure the circle run-out at the center
journal.
 Maximum circle run-out: 0.03 mm (0.001 2 in.)
 If the circle run-out is greater than maximum,
replace the camshaft

Set by Mohammed K. 72
 Cont’d
B) Using a micrometer, measure the cam lobe height.
Standard cam lobe height:
 Intake 38.16 mm (1.5024 in.)
 Exhaust 38.35 mm (1.5098 in.)
Minimum cam lobe height:
 Intake 37.85 mm (1.4902 in.)
 Exhaust 38.00 mm (1.4961 in.)
 If the cam lobe height is less than minimum, replace the camshaft.
C) Using a micrometer, measures the journal diameter.
Standard diameter:
 No.1 journal26.949 - 26.965 mm (1.0610 - 1.0616 in.)
 No.2 - No.7 journals26.888 - 26.975 mm (1.0586-1.0620 in.)
 If the journal diameter is less than specified, replace the camshaft.
•If the, replace the camshaft. journal diameter is less than
specified
 No.2 - No.7 journals26.888 - 26.975 mm (1.0586-1.0620 in.)
Set by Mohammed K. 73
 Task—14: Inspect camshaft oil clearance
Objective:-At the end of the task Material:- Engine camshaft , Cylinder head ,
the student inspect camshaft oil Equipment:-Plastigage , Torque wrench .
clearance
INSPECT CAMSHAFT OIL CLEARANCE
A) Clean the bearing caps and camshaft journal.
B) Place the camshaft in the cylinder head.
C) Lay a strip of Plastigage across each journal.
D) Place the bearing caps with the top of the
number on the cap pointing toward the front and
in numerical order from the front side.

Set by Mohammed K. 74
 Cont’d
E) Install and torque the cap bolts gradually in the sequence shown
in the figure.
 Torque: 200 kg-cm (14 ft-lb, 20 N-m)
 HINT: Do not turn the camshaft while the Plastic gage is in place.
F) Remove the caps and measure the Plastic gage at its widest point.
Standard oil clearance:
•No.1 journal0.035 - 0.072 mm (0.0014 - 0.0028 in.)
 No.2 - No.7 journals0.025 - 0.093 mm (0.0010 - 0.0037 in.)
 Maximum oil clearance: 0.13 mm (0.0051 in.)
 If clearance is greater than maximum, replace the cylinder head
and /or/ camshaft.
G) Clean out the pieces of Plastic gage from the bearing caps and
journals.

Set by Mohammed K. 75
 Task—15: Inspect camshaft thrust clearance
Objective:-At the end of the task the student Material:- Engine camshaft , Cylinder head
inspect camshaft thrust clearance ,Equipment:- Dial-indicator , Torque wrench .
INSPECT CAMSHAFT THRUST CLEARANCE
A) Clean and install the camshaft and bearing caps.
B) Using a dial gauge, measure the thrust clearance while moving the
camshaft back and forth.
 Standard thrust clearance: 0.08 - 0.19 mm(0.0031 - 0.0075 in.)
 Maximum thrust clearance: 0.30 mm (0.01 18 in.)
If clearance is greater than maximum, replace the cam shaft and/or
cylinder head.

Set by Mohammed K. 76
 Task—16: Inspect valve lifter oil clearance
Objective:-At the end of the task Material:- Engine valve lifter , Engine block , Cylinder head
the student inspect valve lifter oil Equipment:- Outside micrometer , Inside micrometer .
clearance.

INSPECT VALVE LIFTER OIL CLEARANCE

A) Using a micrometer, measure the diameter of the valve lifter.
 Valve lifter diameter: 27.975-27.985 mm(1.1014 - 1.1018 in.
B) Using a dial indicator, measure the inside diameter of the cylinder head
bore.
 Lifter bore diameter: 28.000 - 28.021 mm (1.1024-1.1032 in.)
C) Subtract the valve lifter measurement from the cylinder head bore.
 Standard oil clearance: 0.015 - 0.046 mm(0.0006 - 0.0018 in.)
 Maximum oil clearance: 0.10 mm (0.0039 in.)
 If clearance is greater than maximum, replace the cylinder head and/or/
valve lifter.

Set by Mohammed K. 77
Set by Mohammed K. 78
 Task—17: Inspect intake, exhaust manifolds and air intake chamber.
Objective:-At the end of the task the Material:- Engine intake manifold , Engine
student inspect intake, exhaust exhaust manifold , Intake air chamber .
manifolds and air intake Equipment:- Straight edge , Filler gauge .
chamber.
INSPECT INTAKE, EXHAUST
MANIFOLDS AND AIR INTAKE
CHAMBER
Using a precision straight edge and thickness
gauge, check the surfaces contacting the
cylinder head or intake manifold for war page.
Maximum war page:
 Intake manifold 0.10 mm (0.0039in.

Maximum warpage:
 Exhaust manifold 0.75 mm (0.0295in).
Maximum warpage:
 Intake chamber 0.10 mm (0.0039in. Set by Mohammed K. 79
 Chapter Five
Crank gear mechanism (Function, Component parts, Operation)
Function
The crank gear mechanism of an IC engine consists of those parts, which
convert the chemical energy of fuel into heat and then to mechanical energy.

Fig. 5.1. The crank gear

Set by Mohammed K.
mechanism 80
Common block service tasks:

check the block for cracks and

distortion
inspect the cylinders for damage
measure the cylinders for wear
hone or deglaze the cylinder walls
clean the cylinders after honing
install core plugs

Set by Mohammed K. 81
 . Disassembling of Cylinder block, Crankshaft,…
Disassemble the parts in the numerical order shown in the figure.

Set by Mohammed K. 82
 Cont’d
Disassemble the parts in the numerical order shown in the figure.
1. Input shaft bearing 9. Front end plate
2. Flywheel 10. Oil level gauge
3. Rear end plate 11. Engine front
mounting
4. Rear oil seal 12. Oil filter
5. Engine front mounting 13. Engine rear hanger
6. Alternator and bracket 14. Oil pump
7. Water pump and heater hose
8. Drain cock
15. Piston and connecting rod
16. Crankshaft and bearing

Set by Mohammed K. 83
Set by Mohammed K. 84
 Component parts

Cylinder block

Cylinder head

Set by Mohammed K. 85
 Disassemble the parts in the numerical order
•Loosen the connecting rod cap nuts little by little.
•Remove the input shaft front bearing with SST (Special •Loosen the main journal cap nuts
Service Tool). little by little in the proper sequence
•Measure the connecting rod thrust clearance. If it exceeds the as indicated on the repair manual.
limit, replace the connecting rod.
•Remove the crankshaft and keep the
•Mark the connecting rods and caps to prevent changing their
original combinations. bearings and caps in correct order.
•Ream the piston ring ridge at the top of the cylinder. If this •Keep the piston-connecting rod
step is not performed prior to removing the pistons, the piston assembly in correct order.
ring land will be damaged. •Measure the crankshaft thrust
•Cover the rod bolts with hoses to protect the clearance. If it exceeds the limit,
crankshaft pins and cylinder bore from damage. replace the thrust washer.
•Using a plastic hammer tap gently the tip of
connecting rod stud to remove the piston-connecting
rod assembly. Set by Mohammed K. 86
 Inspection and repair Cylinder block
•Clean and check the cylinder block for cracks or scratches.
•Using a precision straight edge and thickness gauge, check cylinder block topside surface for
warpage. If the warpage exceeds the limit, correct by grinding the surface or replace it.
•Inspect for warpage along the lines shown in the figure.
•Visually inspect the cylinders for vertical scratches.
•If there are deep scrathes, the cylinder must be rebored.
•Measure the cylinder bores in axial and thrust directions at the top, middle, and bottom as
shown in the figure.
• If the bore excceds the limit, it must be rebored.
Overheating can cause the block to warp or twist, causing main bearing alignment
problems
Check with a straightedge and feeler gauge lay the straightedge on the bores
slide the feeler gauge between the straightedge
Set by Mohammed K.
and bores 87
 Measuring Deck Warpage

Maximum allowable warpage is about

0.003"–0.005" (0.08 mm–0.13 mm Set by Mohammed K. 88
 Procedure:-
•Take a rough measurement with a vernier caliper. Assume:- 58.00mm
•Transfer this measurement ( 58.00mm) to the external micrometer.
•Select a rod and washer for the bore gauge. 58.00mm + (0.50 – 1.00)mm
Rod = 55.00mm
Washer = 3.00mm
Washer = 0.50mm
•Assemble the bore gauge and set preload to 3 – 4.
•Mounting the bore gauge on the micrometer adjust the larger pointer to zero.
•Take measurements of cylinder bore at different locations.
Measuring taper and out-of-round

Set by Mohammed K. 89
 Cylinder Wear
Cylinder taper
difference in diameter at the
top and bottom of the
cylinder
caused by less lubrication at
the top
Cylinder out-of-roundness
difference in diameters
measured front-to-rear and
side-to-side
piston thrust action makes
the cylinder wear more at
right angles to the crankshaft Set by Mohammed K. 90
 Cylinder Bore Gauge
Slide the gauge up and down the cylinder
Indicator movement indicates changes in diameter

Cylinder Taper

More wear at the top of the cylinder

Set by Mohammed K. 91
Set by Mohammed K. 92
 Cylinder Block Boring Used to rigid hone the cylinders
Removes deep scratches, scoring, or excess
wear
After boring, oversize pistons must be used
The “overbore limit” is the largest allowable
diameter increase typically 0.030"–0.060"

Set by Mohammed K. 93
 Procedure:-
•When reboring the cylinder, rebore all cylinders to the
same size and use an appropriate oversize(o/s) piston.

• Use the following equation to determine the reboring finished diameter.

B=PCH
Where, B is the reboring finished diameter
P is o/s piston diameter.
C is piston clearance
H is honing allowance

Cylinder Honing
Breaks the glaze on used cylinders before installing new rings
Smoothes rough cylinders after boring
Most hones are used in a large, low-speed electric drill Set by Mohammed K. 94
 Cleaning Cylinder Walls
It is very important to remove all honing grit Brush Hone
Grit can act like grinding compound on internal
engine parts
Wash out the cylinders with soap and water
Wipe the cylinders down with an oily rag until they
are perfectly clean

Used for light honing to restore surface

Set by Mohammed K. 95
 Piston, Piston rings, connecting rod,…
•Check the pin fit by rocking the piston at right angle to pin.
If any movement is felt, replace the piston and piston pin.

•Remove the piston rings with a piston ring expander.

•Remove the piston pin.
•Clean the piston, piston rings, connecting rod, bearings, …
•Measure the piston rings end gap with each ring at the
lower part of the cylinder bore where the wear is least.
•Measure the groove clearances.
•If it exceed the specification, replace the ring and/or
piston.
•Check connecting rods for bend and twist.

Set by Mohammed K. 96
 Measuring Piston Clearance
•Subtract the piston diameter from the cylinder
diameter
•The difference equals the piston clearance
Average clearance is about 0.001" (0.025 mm)
•Side clearance is the space between the side
of a compression ring and the inside of the
piston groove
•To measure: insert a new ring into the groove
slide a feeler gauge between the ring and
groove
•If the clearance is beyond specs, replace the
piston or install a ring spacer

Set by Mohammed K. 97
 Measuring Piston Wear
Pistons may require repair
or replacement because of
damage:
 cracked skirts
 worn ring grooves
 cracked ring lands
 worn pin bores
If wear exceeds specifications,
replace or knurl the piston

Set by Mohammed K. 98
Set by Mohammed K. 99
 Measuring Piston Ring Gap

Measuring Piston Ring Side Clearance

Insert a ring into the cylinder and

Set by Mohammed K. 100
push it to the bottom of ring travel
Rods are subjected to tons of force .They may wear, bend, or even break
Rod Small End Service
• Measure the bore with a
telescoping gauge and a
micrometer
• If the bore is worn beyond specs,
replace the rod bushing
• The pin will have to be “fitted” in
the rod
A “rod alignment fixture” is needed
Check to see if the small end and
Set by Mohammed K. 101
 Rod Big End Service
• Remove the bearing insert
• Reinstall the rod cap
• Torque to specs
• Measure the bore diameter on both edges and on both sides
• Any difference in edge diameters equals taper
• Any difference in cross diameters equals out-of-roundness

Set by Mohammed K. 102

Set by Mohammed K. 103
• Make sure the crankshaft is perfectly clean
• Use compressed air to blow out all the oil passages
• Inspect for scratches, scoring, or signs of wear
Crankshaft and bearing
•Clean the crank shaft.
•Inspect the crankshaft for scratch, crack, damage,…
•Check the crankshaft for run out. If it exceeds the limit
replace.
•Measure crankshaft for wear (Taper and Out-of-round). If the wear
exceeds the limit, the crankshaft must be reground or replaced.
•Measure the main bearing clearance. You may use a plastigage
and/or telescopic gauge with external micrometer.
•Measure the connecting rod bearing clearance.
•You may use a plastigage and/or telescopic gauge with external
micrometer. Set by Mohammed K. 104
 Measuring Journal Taper and Out-of-Round
• If one side is worn more than the other, the journal is tapered
– measure both ends of the journal
• If the journal is worn more on the top than on the side, it is out-of-round
– measure across the journal from side to side and then from top to bottom
Measuring Journal, Taper and Out-of-Round

Set by Mohammed K. 105

Set by Mohammed K. 106
Set by Mohammed K. 107
Set by Mohammed K. 108
Set by Mohammed K. 109
Set by Mohammed K. 110
Set by Mohammed K. 111
 Chapter Six
Nature of wear on engine parts
Mechanics of IC engines

• If a technician does not know how to properly diagnose engine problems, time,
effort, and money will be wasted
• An untrained technician may rebuild an engine when a minor repair would have
corrected the fault

Set by Mohammed K. 112

• Excessive oil consumption
• Excessive crankcase blowby
• Noises
• Exhaust smoke
• Poor performance
• Coolant in the oil
• Engine seizure

Set by Mohammed K. 113

 Pre-Teardown Inspection
• Run the engine
• Look for external problems:
Check Oil Condition
– oil leaks • Check for coolant in the oil
– vacuum leaks – shows up as white or milky oil
– part damage • Check for gasoline in the oil
– contaminated oil – smell the dipstick for gasoline

• Listen and watch for problems

Set by Mohammed K. 114

 Engine Oil Leaks External Coolant Leaks
• Causes:
• Causes:
– hose problems
– gaskets harden and crack
– seals wear – rusted freeze (core) plugs
– fasteners work loose – warped, worn, or damaged parts
– parts become warped or cracked • Use a pressure tester to locate leaks
• To isolate leaks:
– clean the affected area
– trace the leak upward to its source

Set by Mohammed K. 115

 Engine Vacuum Leaks Engine Exhaust Leaks
• May produce a hissing sound
• Affect idle quality more than high
speed conditions
– leaks represent a greater percentage of
engine airflow at idle than at high speed
Engine Exhaust Leaks
• Produce a clicking sound
• Causes:
– leaking exhaust gaskets
– a warped exhaust manifold
– loose manifold bolts The leakage path can be easily seen after
exhaust manifold removal
Set by Mohammed K. 116
Engine Smoking

Set by Mohammed K. 117

 Abnormal Engine Noises
• Indicate part wear or damage Compression Test
• Use a stethoscope to find internal noises • Measures the amount of pressure
• A piece of hose can be used produced during the compression stroke
– place one end next to your ear, use the other • Performed any time symptoms point to
end to probe around the engine cylinder pressure leakage
– rough idle
– popping noise in intake or exhaust
– blue exhaust smoke
– excess blowby

Set by Mohammed K. 118

 Cylinder Leakage Tester
• If leakage exceeds specifications, listen
at various points to isolate leakage
• Oil filler cap—ring leakage • After performing inspections and tests,
decide what part or parts must be
• Throttle body—intake valve leakage repaired or replaced
• Exhaust pipe—exhaust valve leakage • Evaluate your pre-teardown diagnosis
• Radiator bubbles—head gasket or • If you still can’t determine the problem,
cracked head, block partially disassemble the engine for
further inspection

Set by Mohammed K. 119

 Burned Valve

Causes an engine miss, a popping sound

atSet the throttle
by Mohammed K. body or exhaust 120
Set by Mohammed K. 121
 Cam Lobe Wear
Camshaft Problems
• Worn cam lobes
• Worn journals
• Broken cams
• Worn distributor drive gear
• Loose or worn fuel pump drive eccentric

Reduces valve lift and power output

Set by Mohammed K. 122
Rocker Arm and Push Rod Problems Valve Train Clearance
• May cause clatter (light tapping noise)
• Rocker arms may wear
• Push rods may be bent
• To check, roll the push rods on a flat bench
Hydraulic Lifter Problems
• Worn or defective hydraulic lifters may
produce valve clatter
• To check, remove the valve cover
• Try adjusting the valves
• If adjustment will not quiet the noise, check
for valve train wear Excess clearance can produce noise
• If the valve train passes, the lifter is bad
• Low oil pressure can cause lifter noiseSet by Mohammed K. 123
 Piston Pin Knock Piston Knock (Slap)
• Results from prolonged preignition or
detonation
• Causes low compression, blowby, smoking,
and rough idle

Burned Piston
• Too much clearance between the piston pin
and the pin bore or connecting rod bushing
• Makes a double knock
• The noise does not change much with Loud, metallic knock that is loudest when
engine load the engine is cold
Set by Mohammed K. 124
Worn Rings and Cylinder

Set by Mohammed K. 125

Crankshaft Problems Rod Bearing Knock
• Journal wear • Light, regular rapping noise with the engine
• Main bearing wear floating
• Loudest after warm-up
• Rod bearing wear
• Caused by wear and excessive rod bearing-
• Low oil pressure to-crankshaft clearance
• To locate, short out or disconnect the spark
plug wires, one at a time
• The knocking bearing may quiet down
when its cylinder is disabled

Set by Mohammed K. 126

 Main Bearing Knock
• Similar to rod bearing knock, but slightly deeper in pitch
• More pronounced when the engine is under load
• Worn bearings and journals are letting the crankshaft move up and down
• Usually reduces oil pressure
• To verify, remove the oil pan and pressure test the lubrication system
• Excessive oil flowing out of one or more of the main bearings implies too much
bearing clearance If the crankshaft is not worn, the bearing inserts may be
replaced

Set by Mohammed K. 127

 Excess Crankshaft End Play
• Caused by a worn main thrust bearing
• May produce a deep knock when applying or releasing the clutch
• On an automatic transmission, a single thud or knock may occur during acceleration or
deceleration Broken Engine Mounts

Broken Engine Mounts

The End!!!
• Allow the engine to move in the vehicle
• To check:
– open the hood
– engage the parking brake
– shift transmission into drive or into gear
– with the brakes on, slowly increase engine speed or
release the clutch pedal
– if the engine moves excessively, the mounts may be broken
Set by Mohammed K. 128