2022

HHM JDT ISLAM

POLYTECHNIC
COLLEGE
AUTOMOBILE
ENGG.DEPARTMENT

[DIESEL ENGINE SERVICE LAB

{4057}]
LAB MANUAL
 CERTIFICATE

NAME :

REGISTER NUMBER:

YEAR OF STUDY :

STAFF IN CHARGE
VISION OF THE DEPARTMENT
TO CREATE GLOBALLY COMPETEND AUTOMOBILE ENGINEERS COMMITTED TO
SERVE THE SOCIETY,CONFIDENT TO START ENTERPRENEURSHIP AND
COURAGEOUSTO BE PIONEERS IN NEW VENBTURES IN AUTOMOBILE INDUSTRY.

MISSION OF THE DEPARTMENT

1.WE PROVIDE OUR STUDENTS ARE STRONG THEROTICAL AND PRACTICAL
KNOWLEDGE IN AUTOMOBILE ENGINEERING AND GIVE THEM A GLOBAL
OUTLOOK
2.WE CREATE FACILITIES FOR CONTINUED EDUCATION,TRAINING,RESEARCH
AND CONSULTANCY.
3.WE MAINTAIN A CLOSE CONTACT WITH INDUSTRY THROUGH OUR ALLIANCE
WITH THE MARKET LEADERS

PROGRAM SPECIFIC OUTCOMES

1.BE AWARE OF THE DEVELOPMENT IN THE FIELDOF AUTOMOBILE ENGG. BY
CONTINOUSLY ENHANCING THEIR KNOWLEDGE.
2.ABILITY TO DIAGNOSE THE TROUBLES OF THE VEHICLES AND TAKE
APPROPRIATE ACTIONS ACCORDINGLY

PROGRAM EDUCATIONAL OBJECTIVES

1.PURSUE A SUCCESSFUL CAREER IN AUTOMOBILE ENGG.OR A RELATED
FIELD ,UTILIZING EDUCATION AND THE CONTRIBUTIONTO THE PROFESSION AS
AN EMPLOY OR AN ENTERPRENEUR.
2.BE ABLE TO USE ADVANCED TECHNIQUES , SKILLS AND MOERN AUTOMOBILE
TOOLS
EXPT.1
MEASURING CYLINDER BORE ( AMBASSDOR)

Aim: Cleaning, checking, and Measuring

Tools and equipments used: cylinder bore measuring gauge with dial
test indicator
Raw materials required: cotton waste, grease, petrol, kerosene oil

Procedure
1. We cleaned the cylinder whose taperness and ovality was to be
measured from inside
2. Set the gauge to standard size of bore i.e.2.875”
3. To measure taperness of cylinder no .1 , set gauge at T.D.C and
made it zero 3
4. Measure taperness by setting gauge at B.D.C. .i.e.0.006”
5. To measure ovality , set gauge at centre of cylinder and ovality
found to be 0.003”
6. Repeated point no.2 to 5 for all four cylinder
7. From readings of taperness and ovality , we calculated the piston
size , which was 0.020” over the standard size
8. These cylinder requires boring and fitting of new pistons
Precautions
1. Standard size should be known before measuring bore
2. Zero should be set , below ridge of cylinder Hand should be kept straight
while doing measurement
3. Right sized plunger and washer should be used with cylinder bore gauge
4. Cylinder bore measurement should be done twice or three times
5. Boring and / or sleeve fitment should be as per manufactures instruction
6. Do not work with dirty hands
Bore size of Different Indian vehicles
Two and three wheelers
Make Engine model Bore size (mm)
Bajaj auto Ltd. Chetak 57.00
Royal Enfield(I) Ltd. Bullet 350CC 69.87
Hero-Honda motors Ltd. CD 100 50.00
TVS Suzuki Ltd. AX 100R 50.00

Cars and Jeeps

MAKE Engine Model Bore size (mm)
Hindustan motors Ltd Ambassodor (OHV) 73.02
Hindustan motors Ltd Ambassodor (High 73.02
Comp)
Hindustan motors Ltd Ambassodor (Strut 73.02
Type)
Premier Automoiles Ltd Premier Padmini 68.00
Premier Automoiles Ltd Premier 118NE 73.00
Premier Automoiles Ltd Premier 137/138D 78.00
Mahindra & Mahindra Willys Jeep 79.37
Ltd
Maruti udyog Ltd Maruti 800CC 68.50
Maruti udyog Ltd Maruti 1000CC 65.50
Hindustan motors Ltd Austin 1.5 lits 73.02
Telco 483DL 83.00

+Light commercial vehicles

Make Engine model Bore size ( mm)
Bajaj tempo Ltd Matador F305 78.00
Mahindra &Mahindra Peugeto XDP90 90.00
Ltd
Simpson & Co Ltd Perkins P4 88.92
Mahindra &Mahindra MD2250 79.37
Ltd
Mahindra &Mahindra MD2350 85072
Ltd
 Mahindra Nissan alwyn Cabstar 576 89.00
Ltd
Ashoka Leyland Ltd Hino- W04D 104.00
Telco Tata497NA 97.00
Telco Tata497( 609 & 709 ) 97.00
Eicher Mitsubishi Canter 100.00

Heavy Commercial Vehicle

Make Engine Model Bore Size (mm)
Telco Tata697NA 97.00
Telco Tata697TC 97.00
Telco Tta692DI 90.00
Telco Tata OM312 90.00
Ashoka Leyland Ltd. AL 0370 103.35
Ashoka Leyland Ltd. AL 0400 107.25
Ashoka Leyland Ltd. AL 0401 107.25
Ashoka Leyland Ltd. AL 0402 107.25
Ashoka Leyland Ltd. AL 0600 121.93
Ashoka Leyland Ltd. AL 0680 127.01
Ashoka Leyland Ltd. Hino WO6D 104.00
Simpson & co Ltd P6 354 98.42
Ashoka Leyland Ltd. 411/412 107.00
Ashoka Leyland Ltd. IVECO 8040.05 104.00

Marine applications

Make Engine Model Bore Size (mm)

Ashoka Leyland Ltd ALM0370 103.35
Ashoka Leyland Ltd ALM0400 107.25
Ashoka Leyland Ltd ALM0401 107.25
Ashoka Leyland Ltd ALM0402 107.25
Ashoka Leyland Ltd ALM0680 127.01

Tractors
Make Engine Model Bore Size (mm)
Auto Leyland T154 73.02
 Escorts ford 3000,6000 106.68
Hindustan machine tools Zetor 2011 95.00
Ltd.
Mahindra &Mahindra Inter B 275 85.72
Ltd
Mahindra &Mahindra Inter 434 88.90
Ltd
Mahindra &Mahindra Mahindra DI 88.90
Ltd
Kirloskar oil Engine Ltd. RA 100.00
Kirloskar oil Engine Ltd. R11 110.00
Simpson & Co Ltd. Perkins P3 88.92
Simpson & Co Ltd. Perkins P3DI 88.92
Simpson & Co Ltd. Chromad 91.47
Simpson & Co Ltd. S32.5 91.47

Industrial and agricultural engines

Make Engine Model Bore Size (mm)
Kirloskar oil Engine Ltd. AV1 80.00
Kirloskar oil Engine Ltd. TV1 87.50
Ruston YDA MK I 111.12
Ruston YDA MK II 111.26
Ruston YADA MK III 101.68
Ruston Y3 WA MK IV 104.68
PH Diesel Indec 87.31
Viliers MK 12 55.06
Vilier MK 25 70.04
Lambardni LDA 450 85.00
Lambardnilda 250 LDA 520 78.00
Lambardni LDA 530 78.00
EL GI Uraca 60.
EL GI Uraca

RESULT:
EXPT.2
OVERHAULING OF CYLINDER HEAD OF DIESEL ENGINE
Aim: Removing, Decarbonising, Checking, Grinding Valve Seats, Injector
Pressure Testing and Refining.
Tools and Equipments Used : Ring Spanner Set (inch), Socket Set (inch),
Double Ended Spanner Set (inch), Flat Screwdriver (8" & I Plier (6n), Injector
Extractor, Valve Spring Compressor, Valve Grinding Stick, Feeler Gauge, Torque
Wrench, Injector Testing Machine, Surface Plate etc..
Raw Material Required: Cylinder Head Gasket, Top Over Hauling Kit,
Valve Grinding Paste, Kerosene Oil, Diesel, Petrol, Engine Oil (20W/40), Emery
Paper, Old Dhoti, Water and Coolant. OIL FILLER CAP

Procedure: were given an engine of Ashok Leyland, which was stand mounted,
to overhaul its cylinder head

Dismounting Cylinder Head

1. Drained out all water/coolant from engine through radiator
2. Disconnected battery wires from terminals.
3. Unclamped water hoses
4. Dismounted air cleaner.
5. Took out inlet rubber hose pipe of air compressor from inlet
manifold
6. Dismounted fuel filters and fuel supply connections of injectors
7. Dismounted injector pipes holding clamps from inlet manifold
8. Dismounted exhaust pipe from exhaust manifold
9. Disconnected temperature gauge
10.Loosened fan belt and dismounted water pump
11.Unthreaded tappet cover bolt and took it out
12.Took out leak off pipe from injectors and pulled out all injectors
with help of injector extractor
13.Dismounted rocker assembly and push rods
14.Unthreaded all nuts of cylinder head from engine
15.Took out head gasket from engine block Drained out all
water/coolant from engine through radiator
16.Disconnected battery wires from terminals.
 17.Unclamped water hoses
18.Dismounted air cleaner.
19.Took out inlet rubber hose pipe of air compressor from inlet
manifold
20.Dismounted fuel filters and fuel supply connections of injectors
21.Dismounted injector pipes holding clamps from inlet manifold
22.Dismounted exhaust pipe from exhaust manifold
23.Disconnected temperature gauge
24.Loosened fan belt and dismounted water pump
25.Unthreaded tappet cover bolt and took it out
26.Took out leak off pipe from injectors and pulled out all injectors
with help of injector extractor
27.Dismounted rocker assembly and push rods
28.Unthreaded all nuts of cylinder head
29.Serrated inlet and exhaust manifold.

Dismantling of Cylinder Head

a. Numbered all valves from 1 to 12 using letter punch.
b. Compressed valve springs with the help of spring compressor and
took out split cones, collar, seal and springs
Cleaning
a. Scrapped oft ail the deposited carbon.
b. Decarbonise cylinder block also
c. Cleaned cylinder head with the help of emery paper.
d. Thoroughly cleaned cylinder head by immersing it a tray filled with
diesel or Kerosene oil
e. Cleaned all passages of inlet and exhaust, and all components.

Inspection
a. Checked unevenness of cylinder head by placing it on surface plate.
b. Checked scratch marks etc.
c. Checked pitting marks on valves and their seats.
 d. Applied emery paste on pitting marks and grind using valve grinding
stick.

Note-If valve guide or valve seat is worn out or the valves are worn out.
Replace all.
e.Checked injector for pressure and dribbling. if nozzle holes are
blocked/clogged, they should be cleaned with the help of cleaning kit
Note- New injector's pressure –175 kg/ sq.cm
Old injector's pressure 160 kg/sq.cm.
If pressure is less than 150 kg/sq.cm. Overhaul injector.

Assembly
1. Fitted all valves in head
2. Mounted cylinder fitted all valves in heads
3. Tighten all cylinder head nuts with a tightening torque of 15 kg.m.
or 110 Ib ft
4. Mounted rocker assembly push rod
5. Mounted all injector and their leak pipe
6. Re-installed connections of exhaust and inlet manifold, fuel lines,
air compressor, water pump, radiator hose and temperature gauge
7. Adjusted tappet clearance. (ln cold condition 0.5m (0.020)
8. Filled radiator with coolant
9. Air bleeded high pressure pipe lines
10.Fitted tappet cover with packing on it.
11.Checked engine oil's level.
12.Re- installed battery connections and started the engine.
13.Checked engine on high, low and idle speed for leakage and noise
14.Engine' s performance was up to the mark

Precautions
1. Head should be kept precisely over wooden block to avoid it from any
scratch, impression etc.
2. Head gasket should be dry while fitting it, No compound etc. should be
applied on it.
3. Proper de-carbonising should be done to head and block.
4. Cylinder head should be tightened in clockwise direction with specified
torque
5. Worn out valve guides, seats should be replaced
6. Properly tight fuel line connection and thoroughly checked for leakage
etc.
7. Less injector pressure should be adjusted followed by its fitment.
8. Valves should be checked for locking etc using cotters
9. Ferrul O ring must be fitted for rocker lubrication, while mounting head
gasket.
RESULT:
EXPT.3
OVERHAULING OF FEED PUMP
Aim: Removing dismantling, cleaning checking assembling testing and refitting
Tools and equipments: Used-Double Ended Spanner Set (mm,) Ring
Spanner Set (mm) Long Nose Plier (6%) , stud plier , small cleaning tray , flat
screw driver (9”) , cleaning brush (2”)
Raw Material Required: Diesel, old Dhoti, Copper Washer Kit for Banjo
bolts small container, flexible flue Pipe

Procedure
1. Unthreaded banjo bolt (19mm) which was threaded to main diesel
line of feed pump with help of ring spanner.
2. Unthreaded outlet diesel line's bolt (19mm) going up to diesel
filters, with the help of ring spanner.
3. Unthreaded feed pump flange's nut (10mm) and serrated feed
pump from F.1.punp.
4. Cleaned feed pump assembly by placing it in a small tray.
5. Loosened and clamping nut and serrated nylon filter and its housing
from feed pump.
6. Clamped feed pump lengthwise in bench vice with small wooden
blocks as their packing
7. .Loosened and dismounted hand priming pump. Took out, inlet
valve and valve return spring from feed pump.
8. Loosened and unthreaded outlet plugs and took out outlet valve
with valve return spring from feed pump.
9. Unthreaded plug screw and took it out from feed pump body. Also
took out plunger, return spring. Pump plunger pressure spindle
from pump body.
10.Took out tappet roller lock from lock groove with the help of nose
plier.
11.Serrated tappet roller assembly from feed pump.
12.Serrated roller and pin from tappet roller assembly
13.Cleaned all components with diesel.
 14.A checked seat of inlet and exhaust valve both does not have any
marks.
15.Checked valve seat of feed pump, that too was OK
16.Checked hand priming pump with vacuum method. (Kept thumb or
a little pressure over threaded part and pulled hand pump. If piston
of priming pump remains lifted it shows there is a leakage and it
after pulling up the pump settles a little down, then it 1s OK)..
17.Rested feed pump's plunger in its body and checked for its
loosening and also checked it using vacuummethod.
18.Checked tappet roller and its pin for their worn out.

Assembling
1. Rested pump plunger, return spring pump housing. Mounted new
copper washer and tighten screw plug(30mm), using ring Spanner
2. Rested roller spring, tappet roller assembly in housing and locked it
using plier.
3. placed inlet and outlet valve at their seat and placed and hand
priming Pump over inlet
4. Tighten outlet screw plug with new copper washer over outlet
valve
5. Mounted new filter housing rubber, cleaned nylon filter and spring
in filter housing and clamping nut by threading it with fingers.

Testing
1. Tighten flexible diesel pipe to inlet with banjo bolt.
2. Immersed the other end in diesel filled jar and moved hand priming
pump up and down. Outlet supply wasquite regular.
3. Mounted feed pump with new packing, over F.1. Pump by
threading all three flange nuts (10mm).
4. Mounted new washer in banjo bolt of fuel line from diesel tank,
connected it with feed pump's inlet valve.
5. Connected filter line with outlet of feed pump with banjo washer in
the bolt
6. Moved priming pump up and down and as diesel starts coming out
of outlet banjo bolt, immediately tighten It with inlet of filter
assembly.
 7. Bleeded air from filter assembly through bleeding screws.
8. Started the engine and varied its speed. Engine was running
properly with varying that speed pump and it ensured usthat feed
pump is working properly

Precautions
1. While working over feed pump cleanliness is important
2. Proper sized spanner should be used while dismantling and
assembling priming pump, outlet valve, screwplug, plunger screw
plug
3. Do not over tight any screw, plug of hand priming pump
4. Pump plungers "O ring should be replaced while repairing it.
5. Always Use new rubber ring of filter housing
6. Never increase length of inlet and outlet valve return springs by
pulling them.
7. Replace inlet and outlet valve seats, it they are pitted or worn.
8. Worn out roller, roller pin should be replaced.
9. Fitment of pump plunger in bore should be checked with vacuum
method,. If this fails replace both.
10.Always new copper washers.
11.Checked hand priming pump with vacuum method.
12.Properly bleed fuel supply system after assembling
13.Fill pump’s lubricating oil, after fitting feed pump to it.
14.Move hand priming pump up and down after installing feed pump
and check pressure relief valve. If it isnot working jam, the fuel line
may damage
Note-Fuel feed pump's pressure should be up to 1 kg./sq.cm.
RESULT:
EXPT.4
OVERRAULING OF FUEL IN.IECTION PUMP
(PNEUMATIC TYPE)
AIM: Removing. Dismantling, Cleaning, Checking, Assembling Testing and
refitting
Tools and Equipments Used: Double ended Spanner Set (inch), Ring
Spanner set (inch) flat screw driver (6 &10). Tray, Swan Neck Pipe (Sill Cut off
Pipe), socket set (inch) hammer, dial test Indicator, Calibration Machine,
Phasing Machine
Raw Material required: diesel, Cotton Waste, Bush, Engine oil

Procedure
1. Disconnected fuel pipe line from fuel pump's inlet and outlet from
F.l. pump's gallery
2. Disconnected high pressure pipe from holder and injector and also
disconnected vacuum pipe and engine stopping wire
3. Dismounted FI. pump by unthread its bolts from foundation of
engine block and coupling
4. Washed and cleaned F.I pump assembly with diesel.
5. Dismounted inspection plate and checked control rack
6. Dismantled governor cover and disconnected diaphragm from
control rod.
7. Unthreaded nuts of flange (coupling) and dismantled it from control
rod.
8. Took out delivery valve from dismantled holder and pulled out
plunger assembly by dismantling lower plate lock. Repeated the
same procedure for rest of all plates Took tappets also
9. Brought out the control rack after dismantled; lock cap nut and
control rack lock screw.
10.Dismounted feed pump from F .I. Pump Dismantled front, rear
plates and the intermediate bearing, brought out the cam shaft.
11.Dismounted base plate from F.l. pump.
 12.Cleaned and checked all components, found that plunges were
defective. Checked taper roller bearing shaft. It was not defective al
all.

Note-Assembly of plunger and barrel is called element.

13.Mounted both side’s taper roller bearings and the intermeadiate
bearing and then the cam shaft in FI. Pump. Adjusted play
14.Placed control rod/rack in F.I pump and locked with its screw.
15.Mounted tappets over cam shaft
16.Mounted plunger, plunger return spring. Regulating sleeve, and
upper washer above tappet assembly, already mounted in fuel
injection pump housing.
17.Mounted all plungers in same fashion above tappets and locked
them.
18.Adjusted element and placed delivery valve on its seat.
19.Mounted washier, spring. peg. rubber sealing ring and holder over
delivery valve and tighten the holder using a socket (11/16”)
20.Placed lock over holder neck and tighten it.
21.Mounted toothed quadrant by the side of control rod and Fl. Pump
housing. Checked governor assembly and found it OK.
22.Replaced inlet and outlet valves of feed pump. Checked piston and
outlet pressure of feed pump, which was found to be up to mark.
23.Mounted and tightened feed pump over cam.
24.Mounted front plate. Connected flange to cam shaft of F.l. Pump
and locked it with a nut.
25.Mounted side inspection cover with rubber gasket after filling the
specified amount of lubricating in the pump.
26.Fixed rear plate and mounted new diaphragm with controlling rod
Fixed diaphragm spring properly andchecked vacuum chamber.
RESULT:
EXPT.5
OVERHAULING OF DISTRIBUTOR TYPE FUEL INJECTION
PUMP (ROTARY PUMP) (LUCAS- CAV TATA SUMO)
Aim - Removing. Getting Over Hauled, Refitting, Timing Setting and Bleeding
Air
Tools and Equipments Used: Double Ended Spanner Set (mm), Ring
Spanner Set (mm), Allen Key (7 mm), Flat Screw Driver.
Raw Material Required-13 mm bolts (2 Nos) of 1.5" to 2" length, Old
Dhoti

Procedure
1. Dismounted the pump from vehicle due to loss in average.
2. Dismounted air cleaner
3. Timing cover was splitted in two pieces, took out first piece with
the help of screwdriver and to remove its second piece, loosened
alternator’s foundation bolts allowed by their unthreading and
taking out clamp. To loosened bolts we used 16, 17 mm sized ring
and double end spanner,
4. Bring gear lever in neutral position before dismounting pump.
5. Disconnected battery connections.
6. Dismounted accelerator cable from F.I. pump.
7. Unthreaded banjo bolts of main fuel supply line and return fuel
pipe line from F.I. pump,
8. If crank is rotated by two revolutions, Cam shaft rotates by one
only. if cam shafts timing gear and F.I pump's timing gear appears
to be in locked position after revolution, then there is no need for
second revolution.
9. Used an Allen key of 7mm to lock flywheel.
10.Rotated crank pulley or fan, while locking flywheel
11.Rotated crank in clockwise direction.
12.While rotating crank if Allen key gets stuck in wheel then slightly
took out Allen key and revolve crank by 10 – 20 mm as there are
two holes in lock position and if we fit Allen key in second hole it
gets stuck with wheel and locks it
 13.Piston no. 1 and 4 will be on TDC and cam and F.l. pump gear's lock
position will be there
14.Thread 13mm bolt to hole provided on F.I. Pump and can gear and
locked pump gear by it
15.Loosened idler‘s bolt timing belt and dismounted timing belt from
cam and FI. Pump gears.
16.Dismounted high pressure lines and serrated them from F .I. pump
and injector and disconnected solenoid switch connection
17.Loosened both bots I3 mm, "which were threaded to plate
mounted on F.I pump Loosened main nut also tighten both 13 mm.
bolt again further loosened main nut resulting F.I pump gear will
come out the main nut is thread in centre of plate having 13 mm
bolts
18.Took out all three foundation nuts and only bolt from timing plate
along with washer Sent the pump to authorized dealer /workshop
to over it
Note: Lucas CAV pump has 3 nuts and one bolt while Mico-Bosch pump has 2
nuts and one bolt
19.Mounted F.I pump at its specified place over timing plate and
adjusted it brought F.I. pump timing mark and timing plate mark in
front of each other and threaded all three nuts and bolt along with
washers . Tightened them using 12 mm and 13 mm sized ring
spanner and double ended spanner
20.Slightly tighten FI. Pump’s main supply pipe and return pipe bolts
with bleeded air from pipesand tighten the hand priming pump.
21.Mounted F.l. pump's timing gear and tighten (slightly) main nut
over the 13 mm bolt which was fitted in place a lock, also tighten
both bolts of plate mounted on main nut fixed F.l pump gear at
specified space
22.Tighten high pressure pipes towards F.l. pump side however kept
loose from injectors end
23.Re-installed solenoid connection and accelerator wire with F.I
pump.
24.Mounted timing belt over F.I. pump gear and cam shaft gear and
adjusted timing with idlerbolt properly
25.Unthreaded both bolts 13 mm from shaft gear and F.I gear unlocked
zed fly wheel by taking out Allen key.
 26.Rotated two or three revolutions of crank shaft with the help of
ring spanner There should not be any noise
27.Started the engine and bleeded air injector holders, which were
kept loose. Tighten them after bleeding
Note: Do not apply heater while doing air bleeding
28.Kept engine on running for approx. 5 minutes and then. Slopped for
checking timing belt’s tension. If it should be tighten again.
29.Again dismounted air filter and mounted upper piece of timing
cover with the help of screw driver alternator bolt
30.Mounted air filter.

Precautions
1. First of all air filter should be dismounted otherwise it. May create
for timing cover.
2. Alternator's bolt should be loosed before dismounting of timing,
cover
3. Battery connection should be disconnected as there is an Allen key
is to be fitted with flywheel.
4. Flywheel should be locked before dismounting F.I pump.
5. While locking o F.I.P. gear and cam gear bolts of 13mm and of
length 1.5"-2" should be used. Smaller length bolts should not be
used.
6. While dismounting or mounting timing belt there should not be any
foreign matter or lubricant etc. on hands.
7. while Fitting or removing F.I.P. gear it should be kept locked with
the help of 13 mm bolt otherwise it will keep on rotating
8. while mounting F.I pump on timing plate, mark of plate and should
be in front of each other
9. Main fuel supply line and return fuel Line should be tighten only
after air bleeding
10.Defective copper s banjo washers should be replaced
11.Attain normal running temperature of engine by keeping it running
for five minutes and belt tension should be checked
RESULT:
EXPT.6

INJECTOR TESTING
Aim: Removing Dismantling, Cleaning, Checking assembling, testing, adjusting
and refitting
Tools and Equipments: Double Ended Spanner Set (inch)
Ring spanner set (inch), bench vice, injector cleaning kit, injector testing
Machine.
Raw Material Required- Old Dhoti, Cotton Waste Steel shims, diesel

Procedure
a. Disconnected high pressure pipes from injector and also the over
flow pipe from injector over flow union
b. Took out injectors from cylinder head.
c. Cleaned injector assembly with diesel.
d. Dismantled injector assembly and washed all components with
diesel
e. Washed nozzle assembly with diesel and cleaned nozzle holes etc.
Using nozzle cleaning kit
f. Checked free movement of needle in its barrel it was not sticky
and was moving freely
g. Threaded lower cap nut to injector body and tighten it properly
h. Mounted spindle, pressure spring, its seat, shims and upper cap nut
and tighten it.
i. Mounted injector assembly on high pressure pipe of testing
machine
j. Built up pressure in testing machine and tested nozzle opening
pressure, it was 170 kg/sq. cm. which is quite low. As per
manufacturer's recommendation it should be 205 kg/sq. cm.
k. .Dismounted injector assembly from testing machine and
unthreaded its cap nut /holder. Placed some thick shims over spring
seat and re assembled all components tighten upper cap nut
l. Mounted injector assembly again on testing machine and
performed all tests e.g. pressure test, spray test, opening test,
 chattering test, overflow and dribbling. Found all injectors working
well in all conditions
m. Mounted injectors properly in cylinder head.
n. Re-installed high pressure pipe and overflow pipe connections.
o. Cranked engine with the help of self starter and bleeded air from
the system. Loosened inlet union of high pressure pipe and when
there are no bubble and only diesel is coming out of it tighten the
pipe line
p. Started the engine and checked engine and injector for missing and
proper working respectively All injectors were working properly

Precautions
a. Injector should be cleaned, using cleaning kit and with proper
methodology.
b. Injector pressure should be kept as per manufacturer's
instruction.
c. Needle and nozzle should be freely moved.
d. Safety guard should be installed close to testing machine.
Otherwise sprayed particles may harm us.
e. Neither hand nor any other part of body should kept in front
of sprayed diesel.
f. Proper torque should be applied to upper and lower cap nut,
to tight it.
g. Self starter/battery should be used to crank the engine while
bleeding air from it.
h. Do not work with dirty hands.
i. Proper tools should be used.
RESULT:
EXPT.7

REPLACING OIL FILTER ELEMENT

AIM: Dismantling. Cleaning. Checking, Replacing, Assembling, Refitting and
Testing
Tools and equipments Used: Double Ended Spanner Set (inch). Flat
Screwdriver (10) screw wrench
Raw material required: oil Filter Element, Rubber "O" Ring Engine Oil,
Petrol, Kerosene oil Cotton waste

Procedure
1. We were given an oil filter of ambassador car to change, which was
choked (clogged)
2. Placed cleaning tray below oil filter housing
3. Unthread centre bolt of oil filter with double ended spanner of size
5/8"
4. Took out bolt from oil filter body
5. Dismounted filter cover and took out all parts of oil filter body Oil
filter element was clogged and shirked and upper oil seal was
broken torn
6. Serrated both connections from oil cap pipe from engine.
7. Cleaned all components with kerosene oil.
8. Checked bye pass hole of oil filter cap and found OK
9. Mounted oil filter cap and both unions over engine.
10. Placed new filter element, spring, rubber seal and centre bolt in
guide plate. Placed rubber seal in upper filter body.
11. Filled engine oil in oil filler and mounted filter cap properly and
tightened it by rotating
12. Starting engine and checked filter body for any leakage etc.

Precautions
1. Choked/clogged oil filter should be replaced
2. Torn out/defective rubber ring should be replaced.
 3. Check bye-pass hole provided in oil filter cap. Ball should be checked by
pressing.
4. Oil filter body should be placed only after filling it with oil.
5. Weak spring should be replaced.
6. If rubber seal provided in spring is defective then place new rubber
washer, seal in guide plate.
7. Filter body should be tightened only by rotating it.
8. Note :Please see two type of oil filters shown in fig

RESULT:
EXPT.8
PRACTICE OF DISMANTLING AND ASSEMBLING
OF AN UNSERVICABLE ENGINE

Aim: Dismantling. Cleaning, Checking and Assembling

Tools/Equipments Used : Double Ended Spanner Set (inch), Ring Spanner
Set (inch), Socket set (inch), Ball Peen Hammer (2 % Pounds), Mallet hammer,
Valve Lifter, Flat Screwdriver (6 ). Plug spanner Ring Compressor, Ring Expander,
Combination Plier (6).
Raw Material Required: Petrol Grease, Emery Paper, Cotton Waste

Procedure
1. We were given Job to dismantle an unserviceable engine of jeep
2. Cleaned the engine thoroughly
3. Unthreaded tappet cover's bolt and serrated the cover from cylinder
head
4. Took-Out the tappet cover exhaust manifold and drive them out
5. Unbolt the bolts of inlet and exhaust manifold and drive them out
6. Opened nuts and took at the rocker shaft assembly and push rod
7. Unbolted the head bolts using socket and handle and serrated cylinder
head from engine block
8. Took out the head gasket from block
9. Inverted block and unthreaded the bolts of oil chamber and took it out
from block
10. Unthreaded the dog nut from crank pulley using ring spanner
11. Drive -ut the crank pulley from crank shafts front end with the help of
a tyre level.
12. Unbolted the timing cover from front end and flywheel from rear end.
13. Unthreaded both bolts at oil strainer and took out oil strainer.
14. Connecting rods were taken out after unthreading big end bolts this
make connecting rods free from crank shaft.
15. Drive-out the piston and connecting rods as a single unit, from
cylinders or bore.
16. Meshed cam gear was serrated from crank gear.
 17. Unthread the bolts of oil pump und took out the oil pump from engine
block.
18. Crank shaft was serrated from block only after unthreading the bolts of
main journals.
19. Using valve lifter, all the four exhaust valves were taken out from
block.
20. Drived out all tappets from block and serrated the cam from block.
21. Using valve lifter, all four inlet valves were taken nut from cylinder
head
22. Studied all components after dismantling.
23. Fitted cam shaft and crank shaft in cleaned engine block.
24. Placed tappets over respective cam and fitted cam gear to it.
25. Inserted and compressed piston and ring assembly in ring compressor
and hammered to drive in respective cylinder and fitted the connecting
rod to crank shaft.
26. bolted the oil strainer to engine block
27. Bolted the oil sump to engine block with a packing between them.
28. Straighten the engine and bolted fly wheel to crank flange.
29. Meshed oil pumps gear to cam shaft and tighten all three bolts of it
30. Placed and fitted al 1hour exhausts valves in block.
31. Placed head gasket before placing cylinder head over engine block.
32. Tightened all head bolt in correct sequence and with specified torque.
33. Fitted rockers and shaft Push rods to cylinder head.
34. Fitted tappet cover after fixing ne required gasket to it

RESULT:
EXPT.9
SERVICING OF DIESEL FUEL FILTER ELEMENT
(PRE AND FINE)
AIM: Cleaning, Checking, Refitting and Bleeding
Tools and Equipments Used- Ring Spanner Set (mm), Double Ended
Spanner Set (mm), Flat Screw driver
(10)
Raw Materials Required: Cotton Waste, Diesel Filters, 'o' Ring.
Procedure
1. We were given diesel filter assembly of Mahindra jeep to service it.
2. Dismounted filter assembly from vehicle by unthreading centre bolts
of fuel filter bowl.
3. Cleaned filter bowl with diesel after taking the element out from it.
4. Cleaned pre filter with the help of cleaning brush and blown out the
inside dirty of both filters.
5. Placed pre and fine filter elements in their respective bowl and filled
both bowls with diesel. Tightened to
6. Tightened central clamping bolts.
7. First bleeded the pre filter followed by fine filter by pumping with
the help of hand priming and feed pump.
8. Bleed F. I. Pump after bleeding of both filters
9. Cranked and then started engine. Checked it for air bubbling.
Starting was up to the mark and there was no.

Precautions
1. Fuel filter bowls should be fitted by rotating them.
2. After cleaning of filter element slight air pressure should be applied to
them.
3. Air vent screws should be tighten only after pressing the hand priming
4. Air vent screws should not be over tighten.
5. Bleeding should be done until there is continuous flow of diesel.
6. FI. Pump should be bleeded after filters
 7. New rubber "o' ring should be used while servicing fuel filters and it
should be fitted properly in respective seat.
8. All bleeding screws, banjo bolts, their washers should be checked
thoroughly and replace, if required.
9. Fuel feed pump's filter element and its bowl should also be cleaned while
performing the operation.
10.Do not work with dirty hands.

RESULT: