Chhattisgarh Swami Vivekanand Technical University, Bhilai

Name of the program: Bachelor of Engineering

Branch: Automobile Engineering

Subject: Engine Reconditioning Lab

Total Lab Periods: 24

Maximum Marks: 40

Semester: VIII

Code: 382761 (37)

Batch Size: 30

Minimum Marks: 20

INSTRUCTIONAL OBJECTIVES

To familiarize the students in

1. Engine Reboring and Crank shaft grinding

2. Valve repairing and refitting

3. Fuel system reconditioning

LIST OF EXPERIMENTS

1. Engine Reboring

2. Crank shaft grinding

3. Valve Seat grinding and Valve Lapping.

4. Silencer Decarbonising

5. Fuel Nozzle reconditioning

6. Fuel Injection Pump Calibration

REFERENCES

1. Manufacturer’s Manual

2. Lab Manual
CYLINDER REBORING-CHECKING THE CYLINDER BORE, SETTING THE TOOLS AND
REBORING

Ex.No:3

Date:

AIM:

Checking the cylinder bore, measurement setting and rebore the worn out cylinder

bore of an IC engine and set the tools and rebore the given cylinder

TOOLS REQUIRED:

Telescopic bore gauge, Vernier gauge,Micrometer,Test lamp ,Machine clamping tool, bore clamp, telescopic
gauge, vernier calipers, ferler gauge, u- clamp and Allen key setting micrometer.

CYLINDER SURFACE:

Normally in the IC engine cylinder wear at the top is maximum and impact scoring mark either thrust axis or crank
pin axis to eliminate the scoring required by boring. The measurement of the cylinder wears, taper and ovality by
using telescopic gauge. These gauge and vernier callipers can be used to measure the worn out bore.The cylinder
ovality and taper should not exceed 0.050mm otherwise u.s.p and blow by will occur Bore dial gauge with setting
ring is also used to measure the cylinder taper is high diffcult for the rings to control by blow gases. The
recondining that have excessive tapper or out of cylindricity is done by boring or reboring.Generally a cylinder
greater than 0.006inches must be rebored and boring is done.

REBORING:

A cylinder that can not be cleaned by boring and it must be done by reboring process boring which rotates a cutting
tool in the cylinder to remove the metals.These operation increase the cylinders bore diameter.

PROCEDURE:

 Initially measure the cylinder bore size at 3 points like top, middle and bottom using
telescopic bore gauge or vernier caliper.

 Set the cylinder bore centre and the font mounted spindle centre by using spring loaded
pin arrangement.

 After ensuring the boring part is rotated at the exact centre of bore , tight the clamp
giving more toque.

 Sides should be bored.

 Set the depth of stopper upto b.d.c.

 Rebore , then clean the ovality, taper , scoring marks e.t.c

 The vertical boring machine is placed on the engine, after it is fixed to the stand.
  Boring machine is fixed to the engine clamp and machine clamp.

 The spindle is lifted and to centered to the cylinder which is to be measured and machines
using the pin and spring.

 The centering pins are introduced into their respective holes and the spring is introduced
over them.

 The spindle is lowered into the bore and the centering pins are extended by turning the
expander knob.

 Machine position is adjusted and the centre pins are extended and brought in such that the
gap between the pins and the cylinders walls are same.

 After fixing the spindle is lifted and the centre pin spring are removed.

 The boring tool is now placed in the holder and the nut above the holder is adjusted using
Allen key to move the boring tool. Its distance from the centre is measured by tool setting
micrometer.

 Tool is set the required length according to the next specified bore diameter and tool
adjusting nut.

 The tool position is fixed using the locker nut on one side, now the motor is started and
the gear is engaged for automatic movement of spindle.

Result:

The IC engine cylinder reboring machine setting and machined to exact size of cylinder bore and tolls
are set and cylinder of the given engine is rebored to the next standard size.

VALVE GRINDING AND VALVE LAPPING, SETTING THE VALVE ANGLE AND CHECKING FOR
VALVE LEAKAGE

Ex.No:4

Date:

AIM:

To perform the grinding , lapping , valve setting and valve leakage in the given valve

TOOLS REQUIRED:

Valve grinding machine,Spanner,Lapping paste

Lapping stick, Cutter seat, compressed air,water and Lathe machine

PROECDURE:
  At first the valve is taken out the valve assembly. Check the valve head for cranking,
valve seat for radial run out in the given valve.

 If there is a good margin still left over it can refaced and reused thus the correct of proper
valve seat cutter assembly with point.

 This assembly is placed on the valve seat which is rotated in the cloakwise4 direction.
The carbon of dust and radial run out on the valve head is grinded and cleaned by using
the valve grinding machine.

 Then the lapping paste is applied over the valve face.

 To rotate valve and lift it during the lapping, suction cup is attached to the stick is used.

 When the lapping seat is important to give a valve reciprocating under a racking motion
not continuously rotary movement. Then the valve is removed in the head and paste is
applied, thus the process is done.

To check up the valve seat and its setting following methods can be employed

 Checking with petrol

 Selection on cup method

 Compressed test

 By blowing compressed air

Compressed test: compression test method is used where the air is pumped with help of rubber and the whole unit
is kept light over cylinder head. After building of pressure at(15 lbs square inch) wait for a few minutes, there
should be no drop in pressure.

Blowing water and compressed air: in this method compressed air is blown through suitable adapted filtered on
manifold.

 Chamber is fitted with water

 On blowing the air. No air bubble should be sealing the water

RESULT:

Thus grinding, lapping , setting the valve angle and checking the valve leakage is done

CALIBRATION OF FUEL INJECTION PUMP

Ex.No:5

Date:

AIM:

To study the calibration of fuel injection pump for a ulticylinder diesel engine.
TOOLS REQUIRED: fuel injection test bench, micro pump.

PROECDURE:

 The calibration test is usually carried to check connect quality of fuel is injected for various
load and speed condition. the rack of the fuel ump under test should be in no load position when
the test bench is started speed is controlled by hand wheel.

 Fit the correct rack setting device4 to the injection pump, remove the tapped inspection cover
gauge restriction wheel cock is kept closed to avoid the damage to pressure gauge set the rack
setting device to zero then connect the flexible supply line to the supply connection build up the
required pressure.

 By closing the valves, inspect for leakage the pump housing around discharge union, air vents
and locking screw. When the counter knob is engaged and start button one electronic
tachometer is pressed fuel will cut off the fuel to the test tub. Then the speed of the varied for
varying load condition and the corresponding fuel quantity injected is noted and the readings
are tabulated.

RESULT: Thus the calibration of fuel injection pump for a multicylinder diesel engine is carried out and tabulated.