Automobile Manual

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1 Part A 2 Cylinder head cover Cylinder head Valve rocker shaft Thermostat housing Piston Piston rings Piston pin Connecting rod Oil gauge Oil pump Cylinder liner Valve rocker arm Valve spring Push rod Valve Camshaft Cylinder block Crank shaft Main bearing Bearing cap Crank shaft gear IC Engine Dismantling and assembling of Dismantling and assembling of Dismantling and assembling of Dismantling and assembling of Dismantling and assembling of four stroke petrol engine and identification four stroke petrol engine and identification four stroke petrol engine and identification four stroke petrol engine and identification four stroke petrol engine and identification 3 of parts of parts of parts of parts of parts Date To dismantle and assemble the given 4 stroke petrol engine and identify the all parts 1 Spanner set 4 Screw driver 7 Hammer 2 Torque wrench 5 Emery paper 8 Cloth 3 Feeler gauge 6 Cutting plier 9 Tray Experiment No 1 Aim Tools required Procedure Dismantling 1 Remove the starter motor the engine front side mounting bracket and the clutch housing the lower plate and loosen the transmission securing bolts after removing the radiator outlet Take off the transmission from the cylinder block Remove the drain plug and drain out the engine oil Remove the clutch cover and clutch disc Remove the fuel pump Take down the alternator Remove the alternator mounting stay Ease out the water pump pulley Remove the crank pulley with special tools flywheel holder 2 3 4 5 6 7 8 9 10 Remove the outside cover on the timing belt 11 Remove the timing belt tensioner after removing a part of the tensioner spring from the water pump securing bolt 4 5 12 Remove the timing belt 13 Remove the camshaft timing belt pulley with special tools camshaft lock holder Similarly remove the crankshaft timing belt pulley l4 15 After removing the pulley key take out the timing belt guide 16 Take down the timing belt inside cover 17 Remove the alternator bracket 18 Remove the water pump case 19 Take off the exhaust manifold cover and the exhaust manifold 20 Remove the oil filter with special tools oil filter wrench 21 Draw bypass hose from the intake manifold 22 Take down the inlet manifold with the carburettor 23 Remove the water inlet pipe 24 Take off the cylinder head cover 25 26 27 While drawing out the rocker arm shaft separate the valve rocker arms Loosen the valve adjusting screws fully Leave the screws in place Loosen the rocker arm shaft securing screws and the rocker arm springs 28 Remove the cylinder head i Use the valve lifter and attachment to compress the valve spring in order to free the valve cotter pieces for removal In this way remove the valve spring and the valves ii Remove the valve stem oil seal from the valve guide and then the valve spring seat iii Using the valve guide remover drive the valve guide out from the combustion chamber side to the valve spring side as shown in figure 29 Remove the flywheel using the flywheel holder 30 Take down the oil pan 31 Remove the oil pump strainer 6 7 32 Remove the three connecting rod caps 33 Install the guide hose over the threads of the rod bolts This is to prevent damage to the journal bearing and the cylinder wall when removing the connecting rod 34 De carbonise the top of cylinder bore before removing the piston from 35 Push the piston and the connecting rod assembly out through the top of the 36 Before pushing the piston out scribe the cylinder number on its crown cylinder cylinder bore Assembly The engine is assembled by using the dismantling procedure in reversed manner Result Thus the given 4 stroke petrol engine was dismantled parts are identified and assembled properly 8 4 Cams Bearing shells Helical gear for lubrication pump Eccentric for A C mechanical Fuel pump Bearing shells Cam Shaft 9 Removing cam shaft replacing timing gears Removing cam shaft replacing timing gears Removing cam shaft replacing timing gears Removing cam shaft replacing timing gears Removing cam shaft replacing timing gears removing valves lapping and removing valves lapping and removing valves lapping and removing valves lapping and removing valves lapping and adjusting valve clearance adjusting valve clearance adjusting valve clearance adjusting valve clearance adjusting valve clearance Date To remove the cam shaft timing gear and removing the valves and adjusting valves clearance Experiment No 2 Aim Tools required 1 Double end spanner set 3 Box spanner set 5 Hammer 2 Ring spanner set 4 Screw driver set 6 Emery sheet Procedure Removing cam shaft 1 2 3 4 Remove the distribution drive shaft Remove the cam shaft and place vertically on the table Clean all the bearing s and cams properly Check and inspect all the parts Replacing timing gear and removing valve 1 2 Remove valve cover plates head and manifolds if necessary Use valve spring compressor to compress spring and remove valve spring retainer valve and spring Use a track to keep valves in proper order so they do not get mixed up 3 With head and valve cover off remove valve guide retainer This is done 4 5 with a driver or with a bar type lifter If guide is struck use special valve guide puller to force it out of block Put penetrating oil around guide to loosen it if it is badly struck To install assembly push it down into position in cylinder block Pull guide down with guide lifter far enough to permit installation of guide retainer Then let guide move upto seat retainer against block 10 11 3 4 2 3 4 5 Replacing timing gear 1 2 Remove the cylinder head from the engine Remove water pump crank shaft cam shaft pulleys and engine belt drive set etc Timing gears should match with the mark given in the 2 gears The above procedure is repeated for assembling Valve lapping 1 Roughing paste is applied to the valve face and head grinding is carried out The faces are checked for the removal of any lines Then smooth paste is applied again for lapping Now due to smooth finish perfect seating takes place Similarly all valves and all valve seats are lapped continuously Adjusting valve clearance 1 2 3 4 Remove the rocker arm cover Run the engine at optimum running temperature Piston is in TDC at end of compression stroke of the first cylinder Take feeler gauge blade to insert the blade in between the valve stem and the rocker arm by adjusting the adjustment screw Adjust the screw so that feeler gauge blade moves to and for freely Tighten the lock nut Next 3 4 and 2 cylinders are adjusted for valve clearance to follow the above


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