Petrol Engines

THE OTOMOTIF COLLEGE
DAT 2401 Petrol Engines

Assignment 1
Diploma in Automotive Technology
A. Junid
(DAT201509-02102)
16 January 2018
DAT 2401 Assignment 1 – A. Junid - DAT201509-02102
Table of Contents
Page
Topic Assignment Questions / Problems...................................................... 2
Answer to Question 1................................................................................... 3
Answer to Question 2…………..................................................................... 4
Answer to Question 3…................................................................................ 8
Answer to Question 4……………................................................................. 9
Answer to Question 5................................................................................... 10
Answer to Question 6…................................................................................ 11
Diploma in Automotive Technology Student Number: DAT201509-02102

16 January 2018 Page 1 of 30
Topic Assignment Questions/Problems:
1. Give the reasons and problems that would need a Petrol Engine to
be overhauled.
2. State the procedure/steps in overhauling a Petrol Engine.
3. What are the common problems/troubles that are most likely to
occur in the Cylinder Head?
4. What are the common problems/troubles that are most happening
at the Cylinder Block?
5. Give other diagnostic tools/SSTs that will determine engine for
overhauling.
6. Include a picture of you doing the task for CYLINDER HEAD,

CYLINDER BLOCK and other tasks in Petrol engine for references

Question 1
Reasons for Engine Overhaul Problems requiring engine overhaul
1 Worn cylinder bore Loss of compression / power
2 Worn / damaged piston rings Loss of compression / power
3 Piston pin excessive clearance Piston knock / noise

(including excessive thrust)
4 Excessive clearance: Low oil pressure

Crankshaft journal / bearing

Crankshaft main bearing

Crankshaft thrust bearing
7 Excessive clearance: valve / Valve noise

valve lifter / shim
8 Valve face damage / wear Loss of compression / power
9 Valve spring damage Valve noise
10 Valve stem / guide damage Valve noise
11 Valve pushrod damage Noise / loss of power
12 Gasket damage / leak Loss of power / coolant / oil. White

smoke if coolant enters combustion
chamber. Bluish white smoke if
engine oil enters combustion chamber
13 Seal damage/leak (including Bluish white smoke if engine oil enters

valve guide seal) combustion chamber

Question 2
Engine overhaul steps:
Step Measurements / tests / Decision

checks done
1 Verify problem(s) Compression test If compression wet test

reported results in increased
Pressure test
pressure, proceed to
Inspect spark plugs Engine Block

overhaul/inspection, i.e.
Check ignition / timing proceed with the following
disassembly steps only
(except step 7).
If compression wet test

has no pressure increase,
proceed to cylinder head
overhaul/inspection only.
Pressure test can

reconfirm the above, and
check whether leakage is
on gasket, intake or
exhaust valve.
If spark plug condition

poor or ignition/timing
offspec, replace / rectify.
Check mounting blocks &
operate engine to see if
overhaul really needed.

2 Check there are

no intake system
leaks in case this
is the actual
problem
3 Remove engine Drain engine oil &

from vehicle & coolant. Inspect oil /
mount on stand coolant for telltale signs
of poor maintenance /
contamination
4 Remove intake & Inspect belts Order replacement if

exhaust necessary
manifolds, water
pump pulley,
alternator,
compressor,
accessory belts
5 Adjust cylinder 1 Replace belt/chain if

to TDC with necessary
timing marks
aligned. Mark
timing points if
needed. Remove
timing belt/chain
cover & inspect
condition/tension.
6 Remove cylinder Measure valve

head cover. clearance if accessible
at this stage & if no
hydraulic lifters

7 Remove Ensure pushrods / lifters Replace components that

camshafts/ / valves / springs / shims are offspec.
valves, pushrods, are kept in correct order.
Damaged valve facings
lifters/ shims
Check valve leakage with sufficient margin may
using solvent/liquid test. be lapped.
Measure lifter & guide Replace any hydraulic

clearances, valve & lifters that rattle
valve guide clearances.
Check valve facings.
Check spring
squareness
Check pushrod/valve
stem/camshaft
straightness, cam
height, guide/stem
projections
8 Remove cylinder Check gasket condition, Replace gasket.

head gasket cylinder head & block
Skim facings if within spec
facings for flatness
(e.g. 0.2mm). If warpage
exceeds this, and if OEM
allows, heat treat to
flatten. Else replace
9 If Step 1 indicated Note: Ensure facing Use correct gasket/sealant

cylinder head cleanliness. where applicable
overhaul only,
assemble in
reverse order
above

Engine block overhaul
Step Measurements / tests / Decision

checks done
10 Remove sump. Measure existing thrust Order / install new

Flywheel cover (if clearances thrust bearings if
any) & flywheel needed
Order new sump

gasket
11 Remove main Measure Order / install new

bearing & journal journal/bearing bearings / crankpin if
caps. Ensure clearance using needed
proper markings for plastigage
Replace crankshaft
correct installation
Measure crank pin bearing seal
order & orientation
journal diameters &
main pin bearing
contact diameter
12 Remove pistons. Inspect piston & rings’ Bore/Replace if

clearances & end gaps necessary.
Measure piston & Sleeving may be done

cylinder clearances & if allowed
roundness
13 Check/rectify facing. Ensure facing Apply correct

Reinstall engine cleanliness. gasket/sealants where
block components & applicable
above reverse order

Question 3
Common problems likely to occur in the Cylinder Head:
1) Worn / damaged valve facings/seats
2) Excessive valve stem / guide clearance
3) Gasket damage/leak
4) Broken valve spring
5) Bent valve stem
6) Bent pushrod
7) Worn shims
8) Worm cam lobes
9) Bent camshaft
10) Warped cylinder head
11) Cracked cylinder head
12) Damaged hydraulic lifters
13) Excessive lifter & lifter guide clearance

Question 4
Common problems likely to occur in the Cylinder Block:
1) Warped facing
2) Broken/worn piston ring
3) Cracked piston
4) Damaged upper gasket
5) Bearing – journal excessive clearance
6) Thrust bearing excessive clearance
7) Piston pin excessive clearance
8) Piston pin excessive thrust clearance
9) Piston – cylinder excessive clearance
10) Leaking sump gasket
11) Leaking flywheel bearing seal
12) Piston ring excessive gap
13) Piston ring gaps incorrectly aligned

Question 5
Other diagnostic tools/SSTs that will determine engine overhaul work:
1) Compression test gauge set
2) Pressure test gauge set
3) Plastigauge
4) Vibration meter
5) Feeler gauge
6) Straight edge
7) Valve squareness tool
8) Dial gauge
9) Telescopic dial guage
10) Internal dial gauge
11) Prussian blue paint (valve facing check)
12) OEM compatible Scan Tool
13) Pulley extractor
14) Vernier caliper
15) Micrometer

Question 6
Photos of work on cylinder head, cylinder block & other tasks.
Compression gauge set

Compression test reading

Engine mounted on stand

Prepare for sump removal

Removing sump

Alternator belt removal

Distributor removal

Crankshaft pulley removal tool

New gasket cleaning

Micrometer reading

Marking cylinder head bolts for angle torquing

Angle torquing

Engine block dismounted to remove flywheel

Cylinder bore diameter measurement using bore gauge

Searching for replacement Piston ring

Bearing cap orientation marking
Thrust clearance measurement at Engine Block Crankshaft

Piston insertion using piston ring compression sleeve

Flywheel torquing to spec

Sealant used for Flywheel cover

Engine Operation/Testing


Petrol Engines

Enviado por

Dados do documento

Direitos autorais

Formatos disponíveis

Compartilhar este documento

Compartilhar ou incorporar documento

Opções de compartilhamento

Você considera este documento útil?

Este conteúdo é inapropriado?

Direitos autorais:

Formatos disponíveis

Petrol Engines

Enviado por

Direitos autorais:

Formatos disponíveis

THE OTOMOTIF COLLEGE

DAT 2401 Petrol Engines

Diploma in Automotive Technology

Diploma in Automotive Technology Student Number: DAT201509-02102

Topic Assignment Questions/Problems:

2. State the procedure/steps in overhauling a Petrol Engine.

3. What are the common problems/troubles that are most likely to

occur in the Cylinder Head?

4. What are the common problems/troubles that are most happening

at the Cylinder Block?

5. Give other diagnostic tools/SSTs that will determine engine for

6. Include a picture of you doing the task for CYLINDER HEAD,

Diploma in Automotive Technology Student Number: DAT201509-02102

Reasons for Engine Overhaul Problems requiring engine overhaul

1 Worn cylinder bore Loss of compression / power

2 Worn / damaged piston rings Loss of compression / power

3 Piston pin excessive clearance Piston knock / noise

4 Excessive clearance: Low oil pressure

5 Excessive clearance: Low oil pressure

6 Excessive clearance: Low oil pressure

7 Excessive clearance: valve / Valve noise

8 Valve face damage / wear Loss of compression / power

9 Valve spring damage Valve noise

10 Valve stem / guide damage Valve noise

11 Valve pushrod damage Noise / loss of power

12 Gasket damage / leak Loss of power / coolant / oil. White

13 Seal damage/leak (including Bluish white smoke if engine oil enters

Diploma in Automotive Technology Student Number: DAT201509-02102

Engine overhaul steps:

Step Measurements / tests / Decision

1 Verify problem(s) Compression test If compression wet test

Inspect spark plugs Engine Block

If compression wet test

Pressure test can

If spark plug condition

Diploma in Automotive Technology Student Number: DAT201509-02102

2 Check there are

3 Remove engine Drain engine oil &

4 Remove intake & Inspect belts Order replacement if

5 Adjust cylinder 1 Replace belt/chain if

6 Remove cylinder Measure valve

Diploma in Automotive Technology Student Number: DAT201509-02102

7 Remove Ensure pushrods / lifters Replace components that

Measure lifter & guide Replace any hydraulic

Check valve facings.

8 Remove cylinder Check gasket condition, Replace gasket.

9 If Step 1 indicated Note: Ensure facing Use correct gasket/sealant

Diploma in Automotive Technology Student Number: DAT201509-02102

Engine block overhaul

Step Measurements / tests / Decision

10 Remove sump. Measure existing thrust Order / install new

Order new sump

11 Remove main Measure Order / install new

12 Remove pistons. Inspect piston & rings’ Bore/Replace if

Measure piston & Sleeving may be done

13 Check/rectify facing. Ensure facing Apply correct

Diploma in Automotive Technology Student Number: DAT201509-02102

Common problems likely to occur in the Cylinder Head:

1) Worn / damaged valve facings/seats

2) Excessive valve stem / guide clearance

4) Broken valve spring

5) Bent valve stem

8) Worm cam lobes

10) Warped cylinder head