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Engine overhauling
Step 2
Assembling: before assembling all parts are cleaned and oiled thoroughly
Major Overhaul:
Major or complete overhauling is done to make an engine work in good condition when it
is beyond repair by normal rectification of defects.. Generally major overhauling involves
removal of engine from the vehicle.
It includes;
• Top Overhaul
• Removal of piston and connecting rods for checking and repairing or replacing
worn out parts
• Honing the cylinders
• Filling new pistons and rings
• Scrapping or replacing the bearings of connecting rod and crank shaft if needed
• Checking the valve timings
• Testing and reassembling
Top overhaul is needed in case of leaking valves, leakage between cylinders or general
power loss with out any noise.
Major overhaul is necessary if there is high oil consumption, piston rings are leaking, and
there is internal noise in the engine
Remove water pump - exhaust manifold – oil filler tube - water outlet fitting – thermostat
– crank shaft pulley – oil pump – crank case ventilation – rocker arm assembly – cylinder
head – oil pan – piston and CR assembly – timing gear – front end plate -= fly wheel
housing – clutch – fly wheel – crank shaft – exhaust valves and spring – cam shaft –
valve tappets
ENGINE TUNING:
This includes readjusting or replacing the parts as required for restoring new engine
performance. This keeps the engine to operate in good mechanical condition. Every unit
of the engine is made to perform at its best after tuning.
Procedure: A typical engine tune includes visual and mechanical checks and also with
instruments
1. Loose the spark plug, start the engine to blow out carbon and dirt, shut of the
engine and remove plugs
2. Check engine compression. If compression ratio is not up to specification
performance engine service to eliminate the trouble.
3. Reinstall spark plug after getting correct compression ratio.
4. Check and adjust or replace distributor cap
5. Inspect rotor. Replace if it is not in good condition
6. Check high tension leads, wires distributor centrifugal advance, vacuum advance.
7. Check distributor contact points, battery charge, water, battery cables, drive belts,
manifold head, control valve, intake manifold, fuel lines, cooling system for leaks,
coolant level, anti freeze protection, accelerator linkage crank case ventilation
8. Clean or replace air filter element check choke valve, carburetor.
9. Joint dwell and ignition timing
10. Check idle speed and mixture specifications
11. Lubrication, lights and horn, head light adjustment
12. Steering system, suspension system including shock absorber, excessive ply in
clutch, brake and suspension system
13. Front wheels and ball joints
14. Tests to find a weak cylinder cranking motor operation, conditions of ignition oil,
condenser air pressure in tyres etc.,
Pollution control technologies used for petrol and diesel engines:
The fuel injection system has no bowl. So the system handles only fuel vapor from
the fuel tank. The canister has two connections. One is the hose from the fuel tank.
The other is purge line to the throttle body. Throttle body and port injected engines
use similar systems. Instead of vacuum operated purge valve, an electric purge
control solenoid may be used.
It mounts on canister or in the purge line. The solenoid is normally open . In many
engines the electronic control module ECM controls the purge valve or canister
purge. The ECM opens the purge valve when the engine has reached normal
operating temperature and is running above idle. The ECM bases its action on data
received from the engine speed and coolant temperature sensors. When the ignition
key is ON, the ECM sends a varying voltage pulse or pulse width modulated signal to
the purge solenoid. Maximum purge occurs when the solenoid de energizes and
opens the purge line. This is 0% duty cycle Minimum purge occurs when the
solenoid energizes and closes the purge line. Since canister purge is an output from
the ECM, this scan tool can read the purge duty cycle. The ECM allows canister
purging to occur only after certain conditions are met. This reduces exhaust emissions
and drivability problems.
Fig35.8 Crouse and angling page 451.
The purpose of exhaust gas recirculation is to remove NOx emission by lowering the
combustion temperature as NOx forms when peak combustion temperature exceeds
3500oF
It recirculates an inert exhaust gas back int0o the intake manifold. The cooler exhaust
gas absorbs heat from the combustion process and reduces the temperature
DISCRIPTION AND WORKING
Fig.454 Crouse and angling 35.B
Catalytic converter:
This converts the harmful pollutants in the exhaust gas into harm less gasses. It is
located in the exhaust system and all exhaust gas must flow through it.
A catalytic convertor will have two different catalysts
1. One catalyst treats HC and CO
2. The other catalyst treats NOx
The catalyst for HC and CO encourages the HC to untie with oxygen to become H2O and
CO2. This type of converter is called oxidizing convertor.
The metals platinum and palladium are used as oxidizing catalysts.
The catalyst for NOx splits it into oxygen and nitrogen by reducing NOx
This is reducing convertor. The metal rhodium is used in this.
Inside the catalytic convertor the exhaust gasses pass over a large surface area coated
with the catalyst. This surface is either a bed of pallets or ceramic honey comb. Vehicles
with catalytic convertor must use unleaded gasoline.
Types of catalytic convertors:
Dual bed catalytic convertor
Three way catalytic convertor
A dual catalytic convertor has two pallet beds one over the other, they are separated by an
air chamber. The upper bed contains catalysts coated with three way catalysts. It not only
reduces NOx but also oxidizes HC and CO. The lower bed serves as a two way catalyst.
It further oxidizes HC and CO. When the engine warms up air from the air pump feeds
into the air chamber separating the bed.