Faculty of Engineering Technology

Assignment

SECTION A – TO BE COMPLETED BY THE STUDENT

Module Automobile Technology I Module ME2316
Title Code
Test Disassembly and assembly of an Test Test -2
topic engine Number
Student’s E.D.Sathsindu Heesara Student M2000804013
Name Number

Lecture’s Mr. Wasabha Samarathunga Date & 2024/12/23

Name Time
I confirm that:
• I have been given a copy of the assessment criteria relating to this test
• I understand the meaning of the terms Cheating, Collusion and Plagiarism

Signature: Sathsindu Date: 23.12.2024

SECTION B – TO BE COMPLETED BY MODULE LEADER/TEAM

Feedback comments on in the class test:

Singed:……………………… Print name :……………………………………….

Date:…………………………………. Unconfirmed mark:……………………………………

Content:
Abstract 01
Introduction 02
Theory 03 - 06
Methodology
➢ Apparatus 07 - 08
➢ Procedure 08 - 09
Discussion 09 - 10
Conclusion 11
References 11
Abstract:
This lab report describes how to disassemble and assemble an internal combustion engine. The
main purpose of the practical is to identify the errors and solve them. When the engine is
disassembled it shows the connection of the cylinder head, Pistons, Crankshaft, Camshaft, and
the other components. This lab report observes how the valves open and close and how to wear
the other components. In the stage of assembling an internal combustion engine mainly focuses
on the components are replaced in the correct place and in the correct order or not. Studying an
engine's performance, engaging in group activities, and learning about mechanical systems can
be shown as the other main purposes of the experiment. The observations and challenges faced
during the practical, the use of automotive equipment, and the correct use of safety methods are
discussed here.
Introduction:
The engine is the heart of modern mechanical machines, Vehicles, and everyday machines that
give power. This lab report teaches you how to disassemble and assemble an engine correctly.
This practical gives you knowledge about the performance and maintenance of the engine.
An internal combustion engine converts chemical energy from combustion into mechanical
energy. Many fixed parts move in various ways to make this process happen. Familiarizing
yourself with these parts and positioning them correctly is important to identifying and solving
real-world mechanical problems. This lab report includes how to use the hands-on safety
methods we obtained, the tools used and how to handle them, and the special methods used in
assembling and disassembling the engine.
Identifying engine components such as cylinder block, crankshaft, camshaft, piston, valve and
timing chains/belts, sump and head, mechanical systems experience in safe handling,
disassembly and assembly of mechanical systems, how the various systems inside an engine
work. Studying, completing a complex task easily, and working as a team are the main aims in
this project.
An internal combustion engine is divided into several types based on fuel combustion and
applications. The most commonly used type of engine is the four-stroke engine. It has four main
stages. They are suction, combustion, power, and exhaust. In each of these stages, the engine
cylinder, which is the main part of the engine, provides support to the other parts. The crankshaft
gets the rotation motion needed to drive the vehicle from the piston. The required air and fuel
mixture is provided at the right time by opening and closing the camshaft valve at the right time
and the combustion gas is discharged. Rotation increases efficiency.
One must use the appropriate tools and equipment to increase accuracy and efficiency in
disassembly and assembly. Tools like screwdrivers, hex keys, handles, torque wrenches, and box
paces are used to loosen and tighten socket wrenches, ratchets, and nuts.
The engine disassembly and assembly lab provide an unparalleled opportunity to get to the heart
of mechanical systems. By combining practical training with theoretical knowledge, this exercise
equips participants with the skills and insights necessary for successful careers in engineering.
The importance of accuracy, teamwork, and safety was emphasized throughout the lab, ensuring
a holistic learning experience. This report captures the technical details of the practice and the
broader lessons that extend beyond the lab, providing a foundation for lifelong learning and
professional growth.
Theory:
An internal combustion engine is a machine that converts chemical energy to mechanical energy
through a full combustion process. Engines are used to generate power for vehicles, generators,
and other machinery. Among the various types of internal combustion engines (ICE), four-stroke
engines are more popular than others because of their higher performance, reliability, and eco-
friendliness. Four-stroke engines complete an engine cycle in four strokes of the piston within
the cylinder. These four strokes are intake or suction, compression, power or combustion, and
exhaust. Two turns of the crankshaft complete all of the strokes. The design of the engine
balances the power generation and fuel efficiency.
The four-stroke engine's performance can be divided into four stages
I. Intake stroke: -
When the intake stroke happens the intake valve opens and the piston moves down from the top
dead center (TDC) to the bottom dead center (BDC). It makes a vacuum in the cylinder and it
wrests the air-fuel mixture to the cylinder.
II. Compression stroke: -
The intake valve closed, and the piston moved from the bottom dead center (BDC) to the top
dead center (TDC). This compressed the air-fuel mixture properly and increased the fuel
mixture's temperature. This is the course to raise engine efficiency and power generation.
III. Power stroke: -
At the end of the compression stroke, the air-fuel mixture was ignited by the spark plug. So the
fuel mixture gets fired and it makes huge power and because of that power piston comes very
fatly from the top dead center to the bottom dead center.
IV. Exhaust stroke: -
The exhaust valves open and the piston moves upwards from BDC to TDC pushing the burnt
gases and it removes the burnt gases in the combustion chamber.
There are so many important components in the four-stroke engine and the key components are,
• Cylinder block,

The main structure of the engine and there are

coolant and oil passages in the cylinder block.
• Piston,

A cylindrical component that moves up and down through the

cylinder and transfers the combustion power to the crankshaft.

• Connecting Rod,

It connects the pistons to the crankshaft and converts the linear

motions to rotational motions.

• Crankshaft,

It converts the piston motion to rotational motion and

distributes that power to the transmission and tires.

• Cylinder Head,

It is located on top of the cylinder block and the combustion chamber,

intake, and exhaust valves, and spark plugs or injectors are included
 • Camshaft,

It controls the timing of the intake and exhaust valves' opening and
closing. It ensures proper airflow inside and outside the combustion
chamber.

• Valvetrain,

Include the valves, pushrods, rocker arms, and springs

• Spark plugs
Ignited the air-fuel mixture in the combustion chamber.
• Oil and lubrication system,
It reduces the friction and wear lubricating moving parts.
• Cooling system,
Include components like radiators, water pumps, and coolant passages to distribute the heat that
is generated in the combustion.
• Exhaust system
Remove the burnt gases reducing noise and harmful emissions.
Disassembling a four-stroke engine is a very patient action. Now we consider the primary steps,
1. Preparation: -
To prove the engine is cool remove the battery and all connected power sources. Get outside all
fluids such as oil, coolant, and fuel. Gather the tools such as wrenches, screwdrivers, and pullers.
2. External components removal: -
Separate the external components such as the alternator, starter motor, intake and exhaust
manifolds, and filters.
 3. Cylinder head removal: -
Remove the cylinder head in the block carefully to undamaging the gaskets and valves.
4. Pistons and connecting rods removal: -
Remove the sump unbolt the connecting rod caps, and carefully slide the piston out of the
cylinder.
5. Crankshaft removal: -
Remove the timing chain or belt remove the main bearing and lift the crankshaft out of the block.
6. Inspection of components: -
Inspect all components that were worn and damaged. Clean the all components for reassembly to
the engine.
Reassembling the engine is the reverse process of disassembly clearance and cleaning is very
important for proper engine operations.
1) Rearrange: -
Confirm that all components are clean and undamaged. Replace the damaged parts such as
gaskets, seals, and bearings.
2) Crankshaft installation: -
Lubricate the main bearing and connect the crankshaft with the block.
3) Pistons and connecting rods: -
Put the piston rings into the piston and lubricate them carefully. Then, put the piston into the
cylinder and connect it to the crankshaft using connecting rods.
4) Cylinder head installation: -
Put the head gasket on the cylinder block. Place the cylinder head and torque the bolts using a
torque wrench.
5) Valvetrain assembly: -
Replace the camshaft, pushrods, rocker arms and valves. Certified the valve clearance.
6) External component reinstallation
7) Fluid filling and final check
Methodology:
Apparatus, equipment, and materials:
1. Engine testing tools

• Torque wrench,
This tool helps to tighten nuts and bolts to recommended values. The device indicates when the
required torque is reached.

2. Engine Disassembly tools

• Sockets and ratchet set,

Sockets are available in various sizes to fit the ratchet. The nuts and bolts are arranged so that
they can be tightened and loosened at different angles.

• Screwdrivers,

A screwdriver is a power-operated tool used to turn screws. A

screwdriver. There are several forms of slotted or "flat head"
screwdrivers.
 3. Engine Assembly tools
• Wrench set,

A wrench or spanner is a tool that provides grip and

mechanical advantage when applying torque to turn
objects - usually rotary fasteners such as nuts and bolts -
or prevents them from shifting.

4. Additional essential tools

Procedure:
First, we took the engine to a place where it was easy to disassemble. It was already separated
from the transmission and mounted on a stand.
If there is a longitudinal engine with a pully-mounted fan, we must remove it second. However,
the disassembled engine is not relevant to this model. Engine mounts were removed. When the
timing belt was removed first, we had to rotate the crankshaft using a wrench until the timing
marks on the crankshaft and the camshaft were aligned, and then we had to loosen or remove the
tension on the timing belt.
There are many kinds of horses connected to the engine. Radiator hoses, Heater hoses, Fuel
hoses, vacuum hoses, air intake hoses, oil hoses, Positive Crankcase Ventilation, Emission hoses,
and crankcase breather hoses are some of them. Using a screwdriver and plier, the radiator hoses
and the house that connect to the oil pump and connect the engine to the radiator were removed,
An oil filter was tried to be loosened by hand. But it is impossible to use a carborundum and
loosen the oil filter. When we touched the cylinder head cover again, we found the ignition
system. First, we pulled out the ignition wire cover. Then, the coil pack was pulled out, and the
spark plug was removed using a 10mm T-shaped wrench. Normally we remove the ignition
system like that, but the disassembled engine has already been removed the ignition system.
The sump nut was loosened to remove the leftover oil from the sump. If there is some oil in the
sump engine was has to turn or rotate above 40 – 45 degrees angle to flow the oil to the outside.
But the engine that we disassembled was haven’t oil. Because it had been used several times
before this practical.
After we leftover the Balts in the tapped cover and it was set aside. Removing the tapped cover
reveals the rocker arms and camshaft. After loosening the rocker arms, it was possible to remove
the rocker arms system. If it is an engine with oil, the oil inside should be removed. After
carefully removing the camshaft, the intake and exhaust valves should be removed.
Since the engine we removed had no valve, we were able to remove everything in the cylinder
head after removing the camshaft. We separated the cylinder head by loosening the bolts
connecting it to the block.
After that, what should be done is to loosen the bolts of the sump and separate the sump from the
engine, and separate the piston from the crankshaft. Still, since the piston had already been
removed in the practical engine, the crankshaft was lifted from the engine and the bearings were
removed.
We cleaned it piece by piece with petrol and let it dry. Then, as I mentioned in the theory, the
engine was installed again, the crankshaft was placed correctly and put the thrust bearing for
prevent it from swinging and assembled the sump to the engine block. After the engine rotate
upwards and put the cylinder head gasket and placed the cylinder head and it was raised to the
block by tightening the bolts. After we placed the camshaft and rocker arms and these also fixed
to the engine using torque wrench just like the earlier bolts.

Discussion:
The disassembly and assembly of a four-stroke internal combustion engine gives a deep
knowledge of the engine components. And how they work as a system and how to produce the
power. This experience helps to develop knowledge about automotive engineering.
Understanding the operation of the components.
In the disassembly, each component observed is very useful for understanding the four-stroke
cycle. The role of some components in below.
1. Cylinder block and piston:
The piston converts the thermal energy into mechanical motion. That is the main concept of the
engine. The accuracy of their alignment in the cylinder, reduced friction, and efficient operation
are reflected.
2. Crankshaft and camshaft:
The timing relationship between these components was observed and showed the role of the
timing chain/belt. This alignment is important to reduce the damage caused by value and piston.
3. Valvetrain assembly:
Examining the intake and exhaust values indicates the importance of timing the air-fuel mixture
intake and exhaust.
4. Oil pump and lubrication system:
The role of the oil pump in maintaining lubrication for moving parts was clear. It reduces friction
and the wear.
Observation during the disassembly
It explained how manufacturers design engines for maintenance and repair. The removal of the
timing belt shows its role in engine timing and the importance of the tension for avoiding slip or
breakage. Demonstrate how throttle bodies, oil pumps, etc... deteriorate over time with operation
and explain the need for regular maintenance.
Challengers and applications:
When we rebuilt this engine, some of the pins were missing, the pins were broken due to
overtightening, the pins were stuck in the pins, and the pin threads came out due to incorrect
tightening. It was our mistake to install the crankshaft without using the thrust bearing.
A problem arose during reapplying due to the wear of the cylinder head gasket. I had a little
trouble going to the installation without knowing that the torque wrench could be used to tighten
the nut. Then, I learned how to use the torque wrench. A problem arose because the hose
connected to the oil pump was rotten.
The reassembly phase emphasized the need for systematic procedures to ensure engine
performance Torque specifications: Bolts and fasteners are tightened to torque values specified
by the manufacturer to prevent damage and ensure proper sealing. Hose and Wire Connections:
Correct reconnection of hoses such as coolant and vacuum hoses, is Essential to prevent leaks or
improper operation. Timing Belt Installation: Proper installation and tensioning of the timing belt
ensures precise operation of the crankshaft and camshaft.
the complexity of internal combustion engines and the high level of precision required during
assembly are shown in this lab report. The importance of preventive maintenance to detect worn
components, such as timing belts and gaskets, which can fail with a big breakage, the critical role
of proper lubrication and cooling in extending engine lifespan and maintaining efficiency, how
small missteps in assembly, such as incorrect timing or insufficient tightening of fasteners, can
lead to significant engine issues are the main proposes.
This practical exercise mirrored real-world scenarios in automotive repair and maintenance,
Professionals rely on the same principles to diagnose and fix engine issues. The lab experience
has illustrated
Conclusion:
Disassembling and reassembling a four-stroke internal combustion engine provided a good
understanding of its parts, their roles, and how they work together. This hands-on experience
connected theoretical concepts with practical skills, increase the efficiency of the four-stroke
cycle and how engines operations.
The process highlights the importance of precision in handling components such as timing belts,
pistons, valves and oil pumps to ensure the engine runs efficiently and reliably. Challenges like
aligning timing marks, checking for wear, and ensuring proper reassembly highlighted the
conditions for careful attention to detail and following manufacturer guidelines.
This lab also stressed the importance of regular maintenance, including checking hoses, gaskets,
and lubrication systems, to avoid engine failure and extend its lifespan. It offered valuable
insights into procedures and resolving common engine problems, equipping participants for real-
world scenarios in automotive repair and engineering.
In summary, this hands-on exercise was very important for the complexities of engine
mechanics, improving technical skills, and developing an appreciation for the clearance needed
in engine assembly and maintenance.

Reference:
https://en.wikipedia.org/wiki/Engine_block#/media/File:Cylinder_block_for_V6_Diesel.jpg
https://en.wikipedia.org/wiki/Piston#:~:text=A%20piston%20is%20a%20component,gas-
tight%20by%20piston%20rings.
https://en.wikipedia.org/wiki/Connecting_rod
https://en.wikipedia.org/wiki/Crankshaft
https://www.hotrod.com/how-to/choosing-valvetrain-components/photos/
https://en.wikipedia.org/wiki/Gasoline_direct_injection
https://www.checkline.com/product/DTW
https://ftaelectronics.com/1-4-1-2inch-ratchet-wrench-automotive-metric-mechanic-4-24mm-
socket-set.html