Course: Automobile Engineering

Topic : Introduction
EMISSION CONTROL & SERVICE

Lecture # 5.1

Dr. K.S.Raghuram
Associate Professor
Department of Mechanical Engineering
Vignan’s Institute of Information Technology(A).
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 CONTENTS
❖Types of pollutants
❖Mechanism of Formation of pollutants
❖Concentration measurements

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 Emission sources in a gasoline fuelled car Introduction – Engine Emissions

Emission sources in a diesel engine powered Car

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 Engine Emissions

Engine Exhaust Emissions Non –Exhaust Emissions

❖ Unburned Hydrocarbons (HC) ❖ Unburned HC from fuel tank
❖ Oxides of Carbon ( CO, CO2) ❖ Crankcase blow by
❖ Oxides of Nitrogen ( NO, NO2)
❖ Oxides of Sulphur (SO2, SO3)
❖ Particulates (PM)
❖ Soot & Smoke
❖ Aldehydes
❖ Lead

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 Vehicular Emissions
Evaporative Emissions Refuelling Emissions
Hot Soak CO2
Running Losses Estimation based on Fuel
Diurnal consumption

Exhaust emissions
Nox, CO, HC

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 Engine Exhaust Emissions

Unburned Hydrocarbons (HC)

❖ Irritate the mucous membranes
❖ Operating conditions 1000- 2000 rpm
❖ It rise rapidly as the mixture becomes richer
than stiochiometric mixture
❖ Incomplete combustion
 Air – fuel ratio
 Improper mixing
 Flame quenching

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 Engine Exhaust Emissions
❖Factors which lead to incomplete flame propagation
❖ Poor carburetion and mixture preparation
❖ Poor ignition system
❖ Scavenging problem due to improper valve overlap
❖ Poor swirl and turbulence
❖ Excess exhaust residual gas within the cylinder
❖Exhaust gas recirculation not properly controlled
Gas Tank 10 %
Carburettor 10%
Crankcase blowby 25%
Exhaust 55%
Total 100%
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 Unburned HC Formation
❖ Crevice Volumes
❖Narrow volumes present around the surface of the
combustion chamber
❖High surface to volume into which flame will not
propagate
❖They are present between the piston crown, piston
rings and cylinder liner
❖Along the gasket joints between cylinder head and
block
❖Along the seats of the intake and exhaust valves,
❖ space around the plug center electrode and between
spark plug threads.

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 CO Formation
❖ Colourless gas of about the same density as air
❖ Poisonous gas, which when inhaled replaces the oxygen in the
blood stream
❖ Slowdown physical and mental activity , Headache
❖ Large concentration can lead to death
❖ Due to dissociation process
❖Loss in chemical energy
❖ Incomplete combustion
❖ It increases during idling and lowest during acceleration
❖ Rich mixture & Poor mixing
❖ CO value does not drop to zero value when the mixture is
chemically correct and leaner
❖ Combination of cycle to cycle and cylinder to cylinder air-fuel
mixture maldistribution
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 ❖Photochemical smog
Photochemical chemical reaction of automobile
exhaust and atmospheric air in the presence of
sunlight

HC + NOx sunlight Smog

❖ Sulphur(SOx)
❖ Fuel specification( Limit 50ppm or mg/kg)
❖ Acid rain problem
❖ At high temp H2+S H2 S O2+ S SO2
2SO2 + O2 2SO3
SO3+ H2O H2SO4
SO2+ H2 O H2SO3

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 Evaporative Emissions
❖Fuel tank losses
❖Carburettor losses
❖Fuel tank losses
❖Fuel volatility
❖The ambient temperature
❖Amount of fuel in the
❖Tank design, location
❖Refueling losses
❖Carburettor losses
❖Running losses
 Losses through vent during operation
• These losses are significant only during
hot condition when the vehicle is in
operation
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 Dirunal Emissions
 It draws in air at night as it cools down
 Take place from fuel tanks and carburettor float bowls (in
engines fitted with carburettors) of parked vehicles.
 Expels air and gasoline vapour as it heats up during the day.
 These could be up to 50g per day on hot days.

Hot Soak Emissions

 This occurs after an engine is shut down.
 The residual thermal energy of the engine heats up
 The fuel system leading to release of fuel vapours.

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 Crankcase blow by
 Leakage past the piston, piston rings from
the cylinder to the crankcase
• Blow by gases are produced in the
crankcase during the normal combustion
process
• Piston blowby increases with engine speed
and in particular as the piston rings and
cylinder bore wears

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 Concentration Measurement
Measurement of HC Concentration

Pollutants are measured in gm/kWh or gm/km.

When HC is heated in hydrogen flame, the high flame
temperature generates ions.
Concentration of ions thus generated is proportional to
the HC present in the sample.
Concentration of ions produces current in an electric
circuit which is calibrated to indicate correct value of HC
on meter scale.

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 Concentration Measurement
Measurement of Smoke
Mainly two types of smoke meter for measure the smoke density.
1.Filter darkening type smoke meter
Prominent manufactures of smoke meter namely Bosch,
Hartridge, Von brand etc. are measuring devices to measure soot
density(gm/m3).
2.Light extinction type
These type of smoke meters can be used for continuous
measurement of smoke whereas the filter darkening type can be
used for measurement of smoke under steady state conditions
only.
The Hartridge and UTAC are the smoke meters of light
extinction type.
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Course: Automobile Engineering

ENGINE EMISSION CONTROL

& SERVICE
Lecture # 5.2
Topic: Methods of Emission control

Dr. K.S.Raghuram,
Associate Professor
Department of Mechanical Engineering
Vignan’s Institute of Information Technology(A).

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 Objectives

•Methods of Controlling

•Engine Modification

•Exhaust gas treatment

•Thermal converter

•Catalytic converter
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 Outcomes of the present topics

•Able to know the Methods of Controlling

•Justify the Engine Modification

•Solve the methods to Exhaust gas treatment

•Discover Thermal converter

•Recommend a Catalytic converter

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 Engine Modification Related to Emission Control
Lower Compression Ratios
•Use of unleaded gasoline to lower HC emissions.
•Lower combustion temperature = Lower NOx emissions.

Smaller Combustion Chamber Surface Volume

• Reduce HC emissions.
• Lowers the amount of heat dissipation out of the fuel mixture.
• Reduce the chance of fuel condensation.

Reduce Quench Areas in the Combustion Chambers

• Lower HC and CO emissions.
•Quench areas- movement of piston too close to the cylinder head.

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Methods of controlling-Engine modification

• Variable Compression Ratio (VCR)

• Modification of Combustion Chamber
Configuration
• Fuel Injection System Modification
• High Pressure Fuel Injection
• Water Injection
• Turbo Charging
• Exhaust Gas Recirculation (EGR)

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Engine Modification Related to Emission Control
Variable Compression Ratio (VCR)
• Higher compression ratio (CR) is always desired to get better thermal
efficiency but it increases NOX emissions

Modification Of Combustion Chamber Configuration

• More complete fuel combustion, and reduced PM emissions occur
when fuel and air are mixed more evenly in the combustion chamber.
• Modern combustion chamber design reflects extensive modelling of
several design elements, including:
1. the shape and depth of the combustion chamber and the piston bowl
2. spiral-shaped intake ports
3. the number of cylinder valves.
4. the placement of fuel injectors

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 Fuel Injection System Modification

• Designing electronic controls and

improving fuel injectors
• Injection pressure, injection timing
and spray location
• Injection timing retard can reduce
NOx emissions
High Pressure Fuel Injection
• mix of air and fuel in the chamber.
• Modern high-pressure fuel injection
systems

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Exhaust gas Treatment methods
• After burners
• Catalytic Converters

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 After burner:
• Air is supplied to the exhaust gases and mixture is
burnt with the help of ignition system.
• The HC and CO which are formed in the engine
combustion because of inadequate O2 and
inadequate time to burn are further brunt by
providing air separate box , known as after burner.
• The oxidation of HC in the after burner depends
upon the temperature of exhaust.

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 Exhaust manifold reactor:
• Minimize the heat loss and to provide sufficient time for
mixing of exhaust and secondary air.

EXHAUST GAS RECIRCULATION (EGR ):

• Reduced NOx in petrol as well as diesel
engines.
• In S.I engines, about 10 percent recirculation
reduces NOx emission by 50 percent.
• A portion of an engine's exhaust gas back to the
engine cylinders
• A portion of the exhaust gases is re-circulated to
cylinder intake charge, and this reduces the
quantity of O2 available for combustion.
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Thermal reactor system:
• Provide adequate residence time for allowing appreciable
oxidation of CO and HC to take place.
• Exhaust temperature is increased by retarding the spark.
• Consists of two enlarged exhaust manifolds which allow
greater residence time for burning HC and CO.
• A flame constantly burning a secondary air pump injects
fresh air into the reactor by reducing HC and CO.
• About 10 to 75 percent of the gas is re-circulated after
cooling in the intercooler to reduce the formation of NOx

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Catalytic Converter system:
• Reduce the toxicity of emissions from an internal combustion
engine.
• Placed inside the tailpipe through which deadly exhaust gases
containing unburnt fuel , CO, NOX are emitted.
• Convert these gases into CO2 ,water ,N2 and O2.
❑Types of Catalytic Converter:
✓3 way catalytic converter
✓ 2 way catalytic converter

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3 way catalytic converter
Reduction of nitrogen oxides to nitrogen and oxygen:
2NOx → xO2 + N2
❖ Oxidation of carbon monoxide to carbon dioxide: 2CO + O2 →
2CO2
❖Oxidation of unburnt hydrocarbons (HC) to carbon dioxide and
water: 2CxHy + (2x+y/2)O2 → 2xCO2 + yH2O
2 way catalytic converter
Oxidation of carbon monoxide to carbon dioxide:
2CO + O2 → 2CO2
• Oxidation of unburnt hydrocarbons (unburnt and partially- burnt
fuel) to carbon dioxide and water:
2CxHy + (2x+y/2)O2 → 2xCO2 + yH2O
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Catalytic Converter system:
• Control the emission levels of various
pollutants by changing the chemical
characteristics of the exhaust gases.
• Allows a partial decoupling of emission control
from engine operation in that the conversion
efficiencies for HC and CO are very high at
normal exhaust temperatures.
• The power loss is about 30% and the fuel
consumption is about 10% more than normal.

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Course: Automobile Engineering
ENGINE EMISSION
CONTROL & SERVICE

Lecture # 5.3
Topic: Use of alternative fuels for Emission Control

Dr. K.S.Raghuram,
Associate Professor
Department of Mechanical Engineering
Vignan’s Institute of Information Technology(A).
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 Objectives of present topic
•Use of alternate fuels
•National and international standards

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 Use of alternative fuels for emission control
• Fuel other than the conventional petroleum fuels (diesel or petrol). It
does not entail solely petroleum (such as solar powered, electric car
or hybrid electric vehicles).
• “cleaner” and safer for the environment.
Reasons To Use Alternative Fuels:
1. Conventional fuels are going to run out
2. To reduce pollution
3. To protect against global warming
4. To save money and reuse waste
5. More convenience :Wireless charging is one of the factors that make
alternative fuels more convenient.

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 Sources of Energy

Conventional /
Non-Renewable

Unconventional
(Non-conventional)/
Renewable

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DIFFERENT TYPES OF ALTERNATE FUELS

 Alcohol fuels (ethanol & methanol)

 LPG
 Hydrogen
 Ammonia
 CNG and LNG
 Vegetable oil
 Bio-Fuel (including Biogas)

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 Properties of Alternative Fuels
1. Combustion and Performance: Heat of combustion, heat content of
stoichiometric mixture, octane number (SI engine) , cetane number (CI
engine), boiling point ( especially cold start), flammability limits
2. Emissions: Chemical composition and nature, adiabatic flame
temperature
3. Storage and Handling: Boiling point, volumetric energy density,
vapour pressure, flammability limits
4. Antiknock Quality : Abnormal burning or detonation in an SI engine .
combustion chamber causes a very high rate of energy release,
excessive temperature and pressure inside the cylinder adversely affect
its thermal efficiency
5. Gum Deposits : Reactive hydrocarbons and impurities in the fuel have
a tendency to oxidize upon storage and form liquid and solid gummy
substances
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Alcohol Fuels: Methanol & Ethanol
 Methanol at present is produced mostly from natural gas
although both methanol and ethanol can be produced from
renewable sources.
 Methanol may be produced near the natural gas field and it
being liquid can be more easily handled and transported over
long distances compared to natural gas.

 Ethanol is produced almost entirely from the renewable

agriculture sources by fermentation of sugar, grains, tapioca,
molasses etc.
• Alcohols in engines may be used as:
 Low concentration ( 5 to 10% by volume) blends in gasoline
 Neat alcohol or high level ( 85% by volume) blends

• Neat ethanol (95% ethanol + 5% water) and anhydrous ethanol

blended up to 20% in gasoline have been widely used in Brazil
during 1980’s. In the USA, use of ethanol was promoted due to
agricultural surplus for blending in the reformulated gasoline as
oxygenate.
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 LPG– General Uses

• Gas phase.
 bi-fuel systems for operation either on gasoline or LPG.
 Better cold start and warm-up characteristics
 HC emissions from LPG vehicles have significantly
lower potential of smog formation compared to gasoline
and diesel fuels.
 Negligible PM emissions compared to diesel.
 Small reductions in CO compared to gasoline as no
enrichment of mixtures during warm up or acceleration
phase is required.
 No significant difference in NOx emissions.

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 Hydrogen– General Uses

 Steam reacts with methanol to generate carbon monoxide and

hydrogen.
 When the temperature is set down, carbon monoxide will be
produced. It can produce carbon dioxide and hydrogen.
 The efficiency rate is around 75%.

 Hydrogen fuel cells generate electricity from oxygen and hydrogen.

 These electrochemical cells generate only water vapour so it is
considered as environment friendly.
 Fuel cells are used in spacecrafts, remote weather stations and
submarines. When in liquid form, it is used as rocket fuel

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Ammonia & CNG– General Uses

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 CNG vs. LPG

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 Summary of present topic
 Biodiesel is a renewable fuel that is produced from a variety
of edible and non-edible vegetable oils and animal fats.
 It is mainly used as Alternative Fuel in Diesel Engine Straight
vegetable oils (SVO) are not considered as biodiesel.
 The straight vegetable oils have a very high viscosity that
makes flow of these oils difficult even at room temperatures
 The vegetable oil esters are practically free of sulphur and
have a high cetane number ranging from 46 to 60 depending
upon the feedstock. Due to presence of oxygen, biodiesels
have a lower calorific value than the diesel fuels
 Use of biodiesel results in reduction of CO, HC and PM, but
slight increase in NOx emissions is obtained.
 Reduction in CO emissions is attributed to presence of
oxygen in the fuel molecule.

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Course: Automobile Engineering

ENGINE EMISSION
CONTROL & SERVICE
Lecture # 5.4
Topic: National and international pollution
standards

Dr. K.S.Raghuram
Associate Professor
Department of Mechanical Engineering
Vignan’s Institute of Information Technology(A).

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CONTENTS

➢ Introduction

➢ Emission Standard

➢ Emission Norms

➢ Classification of Automotive Standard

➢ Bharat Stage Emission Standards (BS)

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INTRODUCTION

• BS is claimed to be first mobile emission testing vehicle in the rail sector

enabling Indian Railway to frame emission standards for long
diesel/organization Director General V. Ramachandran said this is the first
step of Indian railway towards controlling emission on par with
international standards.

• The aim of using the BS is to test exhaust emission level analyze engine
performance improve fuel efficiency and reduce environment pollution.

• The BS will help measure Oxides of nitrogen, particular matters total

hydrocarbon methane, carbon mono oxide and carbon dioxide in
locomotives

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Emission Standards
• Emission Standards are requirements that set specific limits to the
amount of pollutants that can be released in to the environment.
Many emissions standards focus on regulating pollutants released by
automobiles (motor cars) and other powered vehicles but they can
also regulate emissions from industry, power plant, small equipment
such as lawn mowers and diesel generators.

• Vehicle emission performance standard: An emission

performance standard is a limit that sets thresholds above which a
different type of emission control technology might be needed

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 Emission Norms

➢ It was in 1991 that first time emission norms were introduced in India
for petrol cars, diesel cars followed in 1992.

➢ Emission norms means some rules (which

has specified quantity) decided by the govt for control of air
pollution.
➢ Implementation of mandatory catalytic converters in 1995 for
• the 4 Metro cities, thus reducing pollution further.
➢ From 2000,India introduced strict Emission standards modelled on the
European ones. This means the birth of Bharat Norms, with

• the first set of norms known as Bharat stage II, followed by BS III, and
BS IV, BS V,BS VI (BS I was the earlier, Indian standard)

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Classification of Automotive Standard

1. Euro 1/BS 1 came in effect from 2000

2. Euro 2/BS II from 2001

3. BS III from April 2005

4. BS IV from April 2010

5. BS V from 2016

6. BS VI norms adopt in 2020.

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Classification of Automotive Standard

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Course: Automobile Engineering

ENGINE EMISSION
CONTROL & SERVICE
Lecture # 5.5
Topic: Engine Service
Dr. K.S. Raghuram
Associate Professor
Department of Mechanical Engineering
Vignan’s Institute of Information Technology(A)
Visakhapatnam, A.P. India.
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CONTENTS

➢Introduction to Engine Service

➢Service details of engine cylinder head
➢Service details of valves and valve mechanism

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INTRODUCTION TO SERVICE OF ENGINE

➢What is service
A motor vehicle service is a series of maintenance procedures
carried out at a set time interval or after the vehicle has travelled
a certain distance
➢What is overhauling
An engine overhaul is a comprehensive engine tune-up that
involves removing and disassembling a vehicle's engine, testing
all the components, cleaning and replacing parts as needed and
then reassembling the engine. This is done to improve vehicle
performance and prolong the life of the engine.
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Tools and Equipment used in Engine
Overhauling
• 1.Servicing Tools • 2.Testing 3.Measuring
➢ Nozzle Cleaner tools Tools
➢ Valve Seat Grinder ➢ Filler Gauge ➢ Steel Scale
➢ Valve Guide Knurling Tools ➢ Depth Gauge ➢ Micrometers
➢ Piston Ring Compressor ➢ Dial Gauge ➢ Callipers
➢Piston Ring Grove Cleaning ➢ Limit Gauge ➢ Slide Callipers
Machine ➢ Height Gauge ➢ Hook Rule
➢ Piston and rod Aligning Tools ➢ Hole Gauge ➢ Dividers
➢ Screw Driver ➢Radius and Fillet
➢ Hammer Gauge
➢ Stud Remover
➢Injection Nozzle Remover
Tools

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Process of Engine overhauling and servicing

1. Remove Engine
2.Remove Accessories

3.Remove Intake and Valve train Components

4.Remover Cylinder Heads
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5.Remove all Ridges: Two wrenches opposite of each
other give you good control 6.Remove Oil Pan and Inspect

7.Remove Gaskets and Scrape Away Crud 8.Remove Front Cover

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 Remove Crank and Camshaft

9.Remove Pistons and Main Caps 10.Remove Crank and Camshaft

11.Remove Camshaft Bearings

12.Clean the Internal Area
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13.Inspect Cylinder heads Cracks- You Don’t Want To See This

14.Clean the Heads

15.Cylinder Head Disassembly
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 16.Inspect Valve, Springs, and Rotator 17.Inspect For Cracks

18.Valve Grinding
19.Cut & Check Valve Seat
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 20.Valve seat Angles
21.Clean and Inspect Pistons

22.Clean and Inspect the Entire Engine

23.Preparation for Painting
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 24.Paint Heads
25.Paint Block

26.Install Camshaft 27.Measure Ring Gap

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 28.Install and Bolt Main Caps
29.Bolt and Torque Crank

30.Fit the Ring 31.Lube the Rod Bearings

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 32.Prep Pistons for Installation
33.Install Pistons

34.Installing Timing Chain 35.Clean and Prep the Cylinder Heads

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36.Bolt and Torque the Heads 37.Prepare the Front Cover

38.Install Front Cover

39.Install Harmonic Balancer
 40.Prep For Intake Manifold
41.Place the
Gaskets

I42.nstall intake and Distributor 43.Install Oil Pump and Filter

 Valve covers
Carburetor

Water pump

Exhaust manifolds

44. Install Accessories

 Advantages of Engine service and overhauling

• No sudden engine stops

• No time loss
• Effective cost control
• Perfect overhauling engine works more perfect
Service detail of cylinder head
1. Removal of cylinder head
• The various components like the air cleaner carbonate head cover spark plugs
ignition coil, distributor etc are removed as per stop manual.
• The stop manual gives the procedure and order also.
• On L head engines, the manifolds need not be removed and in I –head, the
manifolds should be removed.
• If gasket is stacked a bald is used to remove, such that the pasting surface should
not damage
• Remove manifolds and cleared with cloth.
• Remove rock arm assemblies
• Check rocker area for my sludge, near pattern etc.
• Looses head bolt &nuts, start from center, gradually outwards looses slightly to
avoid the stress.
• After removing bolt & nut, the head can be lifted up.
• Lifting screw is used by inside in spark plug holes
Service detail of cylinder head
2.Cleaning and Inspection
• In case of over head value
• Remove framing corer and examine cam staff and its wear
• Observe the nature of carbon deposits which are in black color, thick and dry, which
are covered due to consumption of high lubrication oil engine running at high speed
as t hot engine conditions.
• Next step clean the head with a clean cloth to remove carbon from can bastion
chamber value seats with help of carbon scrapers called scraping.
• Wire brush is used to clean studs.
• If compressor is availed used compressed hair to blow out Sub sequent clan the
carpets head with kerosene and let it dry.
• After cleaning inspect the cylinder head visually look out for carp age, damaged
machine surfaces & cracks.
• Cap age will indicate misalignment of seats & guides
• To detect cracks, kerosene with cloth and strike again lightly
Service detail of cylinder head

3.Refitting the cylinder head

• Refitting is a reverse process of removal.
• The nuts are fixed in order be webpage of the head.
• Torque squares are used to frighten the bolts
• The sequence of Ashok Leyland vehicle
Course: Automobile Engineering

Lecture # 5.6
Service OF Valves and Valve Mechanism

Dr. K.S. Raghuram

Associate Professor
Department of Mechanical Engineering
Vignan’s Institute of Information Technology(A)
Visakhapatnam, A.P, India.
Service detail of Valves & Valve mechanism
1.Valve removals
• Number with dot pinch as valves and valves holes. Filled with cloth so that the
valve holes are safe that to be plugged.
• Valve lifter is used to remove valves from cylinder head block.
• In valve lifter, the spin is compressed and removes the spring retainer lick and
removing the valves.
• No spring retainers with ford engines in the place that split guide is used.
• It valve is stocked in its guide, simply risen valve stem
• After disassembly clean the valve, guide springs and other parts of valve
members.
• Inspect the parts for any replacements or service
Service detail of Valves & Valve mechanism
2. Valves
• Carbon from the valves is removed by scraping or even chipping which ever
required.
• The scraping or chipping must be done without damage of valves.
• Wire brush mounted in an electric drill used to remove carbon from vale & valve
guides also.
• For valve stems fire abrasive cloth is to e used by fixing and rotation of valve in a
lathe chuck
• After chipping clean with kerosene and dry with a clean cloth.
• Inspect the valve and replace if ,
• They are cracked, destroyed as badly pitted,
• They are work.
• they are excessively bent by checking radian run out as shown in fig-5
• The stem clearance is 0.03mm or more.
Service detail of Valves & Valve mechanism
2. Valves (Contd..)
• If valve are not replaced them same valves are replaced valve replacing machine
• It consist of grading wheel operated by electrical motor .
• The valve is hold in chuck which is rotated by electric motor.
• The machine has further to move valve at 30 to 450.
• The valve replacing machine is used to produce no. of cuts until no more nuts &
scratches as they face of valves
• Diamond dress tool is used and keep 1.5 mm gap or margin.
• Aluminized valves are to grinded since it looses caresses resistance proportions if
bent replaced with new one.
• Valve lapping is done as special purpose machines; these are used if special
refrigeration is not available.
Service detail of Valves & Valve mechanism
• The lapping compound which is the farm of paste is applied to valve face &valve is
happed into t he guide hole.
• .Valve stick is moved until pits on valves are disappearing.
3.Valve seats
• Valve seat purpose is to produce seal proof.
• The seal proof depends on seat angle, which depends on cooling of valve in
particular in exhaust vale)
• Wider the contrast, better it is bit wider should have
• The best valve of valve is generally kept about 2mm
• Internal seal which is cast iron, is made with hard seat cutter, in case insert type
which is made of harder metal, valve seat grids is done using special grinder using
abrasive stores.
• If no. of grinders of the same may be narrowed down to desired with wheel of 300
for 450 seat for better result less grinding angle is used at top side and lower
grinding angle i.e 450-600 at lower side)
Service detail of Valves & Valve mechanism
Valve seats (Contd..)
• If move seat near incase of special alloy steel inserts, and badly worked, then the
insert may be replaced.
• To remove the insert holes are drilled on the thickness, then harming with chisel,
which may loosen and come out.
• Major care that the counter
• If damaged the counter bore recounted bore to next side and fix next side inserts.
• Coat the valve face highly with Prussians blue and press if on valve seat.
• Valve guides may be cleared with wire brush in an electric drill as special cleaner
which has blades.
• After clearance, valve stem clearance is to be checked.
• Valve is moved by car and dial gauge reading will confirms valve guide clearance.
• The valve guide clearance for intake valve is 0.125 mm and for exhaust valve
0.150mm.
Service detail of Valves & Valve mechanism
4.Tappets:
• Inlet valve operation is noisy faulty tappets is one of reason
• The valve tappet is inspected for any cracks and replace if necessary.
• Tappet clearance is also to be checked.
• The clearance in tappet as oil clearance is a out 0.2 n gunny oil on tappet will be 0
fault and removed.
• To avoid faulty oil the following are maintained
1. Oil galleries with clean oil
2. If tappets are wormed replaced with new tappets.
3. Inspect entire valve holes and replace any defective component.
4. Use new oil filters for clean oil.
Course: Automobile Engineering

ENGINE SERVICE

Lecture # 5.7
Topic: Piston, Connecting Rod Assembly

Dr. K.S.Raghuram
Associate Professor
Department of Mechanical Engineering
Vignan’s Institute of Information Technology(A).

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CONTENTS

➢ Introduction

➢ Piston

➢ Piston Components

➢ Connecting Rod

➢ Connecting rod Assembly

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Outcomes of the present topic

➢ Understand the importance of piston

➢ Piston parts and its components

➢ The application of Connecting Rod in automobile engine

➢ The procedure of Connecting rod Assembly

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INTRODUCTION

• Before inspecting the piston , it should be thoroughly

cleaned so as to remove all carbon
• Carbon inside the piston & and on crown is removed by
scrap and piston grooves are cleared with piston groove
cleaner
• Piston skirt cleaning is very important, since scrapping
is not allowed.
• After clearing the piston is inspected for pitting scorch
cracks, scuffing, collapsed skirt etc.

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Piston Components
• Piston rings
• It is checked for uneven wear, less of tension
scratchers
• Once rings are removed should place new piston
rings.
• If engine with low milage its rings are to be
replaced.
• Over size piston rings over size piston is not
allowed.

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Piston Components
• Piston pin
• It is inspected for wear & scats.
• The clearance is to be checked between piston pin
and small end of connecting rod
• Its available valves are 0.025mm.
• If more clearance, the piston boss is removed and
over size new pin installed.
• During reaming, the piston is fixed in a vice and
make alignment of holes on the piston.

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• Connecting rod
• It mainly inspected for alignment & near bearings
• Oil holes are also checked, such that they are not
clocked.
• On rotating the crank shaft, the big end moves to
& fro on the pin, if must be mis alignment then
removed and straightened or replaced
• Clearance between bearing of big end of correcting
rod and crank pin also checked result excessive
consumption of lubricating oil.
• The bearing clearance can be measured by
following methods.
• With internal & external micro meter

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• With internal& external Micro meter
• The internal diameter of the connecting rod bearing
is measured using internal micro meter.
• Before measurement, the big end of connecting rod
is righted with specified torque on the bolt.
• The dia is to be measured at different point, and
max- valve is to be known.
• The dia of crank pin (Externals is to be measured
using external micro meter.
• The clearance is obtained by support the outer dia
of crank pin with internal dia of connecting rod.

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With feeler gauge:

Keep feeler gauge of 6mm wide & 0.05mm

thick, between bearing and crank pin tightened
with specified torque.

Rotate gig end about pin

If any change in movement is felt the clearance

is certainly more than specified.

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With plastic gauge:
•It is made by perfect circles corporation, USA to
measure the bearing clearance
•A Plastic material fine thread is placed, and is scale
given the clearance
•The gauge is placed in cross direction on the inside of
bearing and tightened using bolt with specified Torque.
•The charge of shape and condition of looseness of
bearing & read by plastic gauge.
•The allowable clearance is 0.04mm
•It is of insertion type as adjusted type.

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Course: Automobile Engineering

ENGINE SERVICE

Lecture # 5.8
Topic: Cylinderblock, Crankshaft and main
bearings, Engine Assembly- Precautions

Dr. K.S.Raghuram
Associate Professor
Department of Mechanical Engineering
Vignan’s Institute of Information Technology(A).

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 Objectives of the present topic

•Cylinderblock,
•Crankshaft and main bearings,
•Engine Assembly-
•Precautions

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 Outcomes of present topic
•Analyze the Cylinder block
•Examine the crank shaft
•Analyze the crank shaft main
bearings
•Analyze the entine reassembly

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Main bearings
•These are checked for wear
•Feelar gauge on plastic gauge inside and outside micrometer are used to
check the ear which is same as in service of connecting rod.
•The bearings of insertion type and cast type.
•If new bearing is installed too much and & taper, then failure will result
•To check the saddle fore, valve gear, and other necessary components
are removed and the engine placed upside doom
•The specific valves of ovality is 0.05mm.
•The ovality as taper is removed by marching or use original size bearing.

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. Engine Reassembly
•After Over Hauling, the following steps followed in engine
reassembly
•Install the rear main oil seal the crank shaft and the new
main bearings are lubricated and bearing are fixed to
required torque.
•Timing gear, specked, chains etc re aligned and installed,
The black lash is timing gear or chain is checked.
•Piston connecting rod assembling are installed.
•Oil pup cleared and lubricated & installed with new gasket
& seal.
•The oil pan is installed with new gasket.
•Install cylinder head, place valve lifters and push rod
followed the rocker arms.
•Fix the intake manifolds to the cylinder block using gaskets.
The water pump out let than installed
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Precautions
•The following general precautions are followed for safety
•Hot engine parts should be handled with care.
•Hot lubricating oil i.e lubrication oil from hot engine should be
removed with care, since oil is in hot condition.
•Be careful, while removing radiator cap, since the hot water may
flow.
•There are many heavy parts, use proper equipment handle otherwise
injury or in the part being damaged.
•Mostly engine surface are precession machine, handle with care to
avoid damage of parts.
•Wrong electrical connection should be avoided
•Maintain cleanliness of not only the engine parts, but also the entire
service recorded because small amount of dirt may damage safely.

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All the images, videos embedded in
this presentation are collected
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educational content and is not used
for commercial purposes.

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