ASSIGNMENT

ENGINE OVERHAULING

SUBMITTED BY SUBMITTED TO
Y-155 Capt
Pa-60968 DS
Capt Touseef Ahmad Capt Masooma
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LIST OF FIGURES

Figure 1: Removal of elec assys

Figure 2: Exploded View of Disassembled Engine

Figure 3: Cleaning of Parts

Figure 4: Cyl block and feeler gauge

Figure 5: Measuring bore diameter

Figure 6: Connecting rod twist and bend test

Figure 7: Inspecting Crankshaft

Figure 8: Floating Test

Figure 9: Dynamometer

Figure 10: Compression Test

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ENGINE OVERHAUL

Intro

1. Engine overhaul is basically giving your engine a new life. Most engine wears out
over time due to heat and normal wear and tear. Everything has a shell life. And engine
is no different. When you notice your engine oil level is always dropping, fuel efficiency
is not as good as before or there are weird sound coming from the engine, it’s best to
consult a mechanic to check of there is a need to overhaul your engine.

Overhauling your engine is not a simple task. It consist of deconstructing of the engine
and having new internal components such as new pistons, piston rings, main bearings,
valves and springs. There are many more steps to be listed but just know that other
than the engine, everything inside will be new

Seq

2. Fol seq will be fol:-

a. Disassembly of engine
b. Cleaning of components
c. Test to check Cracks
d. Tests on Engine Block & Head

Disassembly of Engine
3. Dis-assemble engine in the fol steps:-
a. Drain oil & coolant from the engine.
b. Remove coolant hoses and fuel lines.
c. Remove all Elec assys (incl Alternator, self-starter & turbocharger).

Figure 1 removal of elec assys

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d. Remove Tappet cover.

e. Remove Fuel filter, fuel pump.
f. Take off Timing belt and pulleys.
g. Remove injection pump.
h. Remove water pump.
i. Engine Head is separated from engine block.
j. Remove Oil pump & Oil sump

Figure2 Exploded View of Disassembled Engine

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Cleaning of engine components

4. After disassembly of an engine, parts are removed and dipped into hot water and
then in kerosene oil for cleaning purpose .After that they are washed by high pressure
cold water.

Figure 3 Cleaning of Parts

Tests on Engine Block & Head.

5. Tests to Check Cracks. Crack detection requires some special equipment. No

single crack detection technique is sufficient for finding cracks in engine parts. One
“quick check” for coolant leaks in used cylinder heads or blocks that requires no
equipment is to simply note the appearance of the combustion chambers and pistons
when the engine is disassembled. If a combustion chamber or piston lacks the normal
accumulation of carbon deposits, it probably has a coolant leak in the head or cylinder.
No crack test was being done as the machine was faulty. However dye penetrant using
calcium carbide is an eff method to check cracks.

6. Engine block Flatness test. An engineer’s straight edge can be used to

check that an engine block or cylinder head is flat by being placed across its
surface.Place the straight edge in such a way so that arrow on the straight edge should
be pointing downwards. Check the gaps according to the manual of the veh (if any) .
Any gaps should then be measured using a feeler gauge. This process has to be
repeated across six areas of the cylinder head. If gaps in any area are outside of the
permitted tolerance for that engine, then the cylinder head will need resurfacing. This
process then has to be repeated on the cylinder block in order to achieve a fit within the
tolerances for the cylinder head and block combined.

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Figure 4 Cyl block and feeler gauge

7. Inspection of cyl bore diameter. There are 3 sizes of std cyl bore diameter .
using a mercer gauge , measure the cyl bore diameter at top , mid and bottom posn in
thrust axial direction. After taking the reading consult the manual if the diameter is
greater than max , rebore all cyl according to the manual specifications. If necessary ,
change the cyl block . If the wear is less than the given std size , use a ridge reamer to
machine the piston ring ridge at the top of the cyl. By inspecting cyl bore diameter we
can check the ovality and taperness of cyl block.

If new sleeves are req to be installed , we will first press the sleeves into cyl block and
then bore the sleeves according to the manual specification . After that boring and
honing process is being done.

Figure 5 Measuring bore diameter

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8. Boring and Honing. Cylinder boring is a process where a specialized machine &
tooling removes the damaged material from the cylinder walls by spinning a special
carbide tool inside of the cylinder. This tool cuts away the damaged area of the cylinder
walls so that the piston can move up and down with minimal friction and allows for max
compression.

Honing is the process of polishing the cyl walls.

9. Inspection of piston and connecting rod assemblies. Fol is procedure:-

a. Using micro meter, measure the piston diameter at right anglesto the
piston pin center line.

b. Measure the cyl bore diameter in the thrust directions.

c. Subtract the piston diameter measurement from the cyl bore diameter
measurement .

d. Consult the manual and check if the oil clearance is greater than max,
replace all 4 pistons and rebore all four cyl.

e. When installing a new piston, install one with the same number mark as
the std bore diameter mark on cyl block.

10. Inspect connecting rod. Fol is the procedure:

a. Using rod aligner , check the connecting rod alignment.

b. Check for bending . if the the bent is greater than max , replace the
connecting rod assy

c. Check for twist. If twist is greater than max , replace the connecting rod
assy.

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Figure 6 Connecting rod twist and bend test

11. Inspection and Repair of Crankshaft. Fol is the procedure:-

a. Place the crankshaft on V Blocks.

b. Using a dial indicator, measure the diameter of the crankshaft at the main

journal and big end .

c. If necessary, grind and hone the main journal and/or crank pins, according

to the manual specifications.

Figure 7 Inspecting Crankshaft

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12. Thrust Clearance of Crankshaft. Using a dial indicator, measure thrust

clearance while prying crankshaft back and fort. If thrust clearance is greater than max,
replace thrust washers as a set.

13. Floating Test. It is conducted to check smooth rotation of crankshaft on

crankcase.

Figure 8 Floating Test

14. Cyl Head Flatness Test. As above mentioned , Using a straight edge and
thickness gauge, measure the surfaces contacting the cyl block manifold for warpage,If
the warpage is greater than max , replace the cyl head.

15. Inspect and Grind Valves. Fol is the procedure :-

a. Grind the valve enough to remove pits abnd carbon.

b. Check that the valve is ground to the correct valve face angle.

c. According to the manual check the valve head margin thickness. If the

thickness is less than min, replace valve.

d. According to the manual check the valve overall length, if the overall

length is less than min, replace the valve.

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16. Cleaning Valve Seat. Fol is the procedure:-

a. Using a 45 deg carbide cutter, resurface the valve seats. Remove only

enough metal to clean.

b. Check the vlave seating posn.

c. if the seating is too high on the valve face, use 20 deg and 4 deg cutters to

correct the seat.

d. if the seating is too low on the valve face , use 75 deg and 4 deg cutters to

correct the seat.

17. Dynamometer. A dynamometer is a device for measuring force, moment of

force (torque), or power. For example, the power produced by an engine, motor or other
rotating prime mover can be calculated by simultaneously measuring torque and
rotational speed (rpm)

Figure 9 Dynamometer

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18. Compression Test. After Complete overhaul compression test is being

performed. A compression test is one of the most common methods for determining
the mechanical condition of an engine. Two type of Compression test are performed.
One is Dry test which is after the complete overhaul while other one is wet test
which is done before overhaul.

Figure 10 Compression Test

19. Recoms

a. Crack test must be carried out.

b. Workers must wear safety helmets, goggles and gloves.

c. Worker should consult manuals to cross check.

d. Manuals should be aval on the benches.

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