PUSAT PENGAJIAN KEJURUTERAAN MEKANIKAL UNIVERSITI TEKNOLOGI

MARA KAMPUS PASIR GUDANG

LABORATORY ASSESSMENT SHEET

MEV300

AUTOMOTIVE SERVICE WORKSOP LAB

LAB TITLE : ASSEMBLE PISTON TO ENGINE BLOCK

PREPARED BY:

NAME GROUP UiTM ID NO. SIGNATURE

NIK DANIEL HAZIQ BIN NIK AZMAN J4EM1105E 2020475204
NUR ALIESYA MOHAMAD SAIFOL J4EM1105E 2020895178
SITI RAFHANAH BINTI SUWANDI J4EM1105E 2020868372
SYAZWAN NAIM BIN SAHILLAH J4EM1105E 2020494282

DATE PERFORMED : 19 / 12 / 2022

DATE SUBMITTED : 26 / 12 / 2022

LECTURER : SIR MIQDAD BIN KHAIRULMAINI

For office use only

ASSESSMENT

CRITERIA FULL SCORE

MARK
1 Division of tasks into groups 2.5
2 Report the data 2.5
3 Summary/Conclusion 2.5
4 Select appropriate references to understand the 2.5
process or concept of the lab session.
TOTAL 10

LAB MANUAL MEV300

AUTOMOTIVE SERVICE
 WORKSHOP

LAB 2: ASSEMBLE CYLINDER HEAD - TIGHTENING BOLT SEQUENCE

1.0 INTRODUCTION

All engines use a cylinder head to seal the top of the cylinders which are in the engine
block. It contains cooling fins or water jackets and valves. Besides, the cylinder head on
overhead valve (OHV) engines contain both intake valves that allow air and fuel into the
cylinder and exhaust valve, which allow the hot gases left over to escape from the engine.
As shown in Figure 1, cylinder heads are constructed of cast iron or aluminum and are then
machined for the valves and other valve-related components.

Figure 1: A cylinder head with four valves per cylinder: two intake valves (larger)
and two exhaust valves (smaller)

2.0 OBJECTIVE
• To understand and show the correct step should take in tightening cylinder head bolt
according to the sequence and correct amount of torque.
• To prepares report and communicate effectively in a group relating to the correct order
in tightening cylinder head bolt with the correct amount of torque

3.0 THEORY

3.1 Torque Wrenches

Torque is the measurement of the twisting effort required to tighten a fastener.

 Tightening to the wrong torque can distort an engine’s cylinder block. Every mechanic
needs to follow the original equipment (OE) manufacturer’s torque and fastener
recommendation. The amount of torque applied to a fastener is measured with a torque
wrench as shown in Figure 2. Torque wrenches are mechanical or digital and the
metric measurement of torque is the Newton-meter.

Figure 2: A “click” torque wrench

3.2 Cylinder Head Installation

Cylinder head bolts must hold against the pressure of combustion that is trying
to push the head off the block. The clamping pressure on the bolts is greater than the
combustion pressure, so the head bolts never feel stress if the proper bolt is maintained.
Head bolts should be torqued in the sequence prescribed in Figure 3. This torque
pattern ensures that the fasteners will be pulled evenly against the head and block. It
is advisable to torque the head in three or four stages in sequence so that to get an
accurate reading with a torque wrench.
 Figure 3: Follow the cylinder head bolt tightening sequence

4.0 APPARATUS & PROCEDURES

Apparatus

4 3

Figure 4: Apparatus

1. Torque wrench
2. Socket wrench 10mm
3. Socket extension
4. L-type socket wrench

Procedures
 1. The bolts and nuts fastened to the cylinder head are removed using a socket wrench of
10mm size and an L-type socket wrench linked to the socket joint.
2. Following that, the bolts and nuts are set out on the table for a cursory inspection.
3. Next, bolts and nuts are positioned correctly and manually tightened by hand first.
4. The bolts are tightened according to the sequences specified in Figure 3 using a torque
wrench set at 30 N and a socket connection with a 10 mm socket wrench. Torque
wrench is made sure to use in 90-degree condition to ensure all the bolts are brought to
their yield strength points.
5. Step 4 is repeated using a torque wrench with the settings of 40 N and 50 N to make
sure the bolts and nuts are properly tightened.

5.0 RESULTS AND ANALYSIS

1 2

4
5
3

Figure 5: Cylinder Head

No. Component Function

1 Camshaft Operate to open and close the valves.

2 Rocker shaft
Transmit the movement of camshaft to the intake and exhaust
valves.

3 Intake Ports Circulate air into cylinder head and combustion chamber.
4 Head valve
Prevent the entry of air and fuel into the combustion chamber.

5 Spark plugs Supply power to ignite the air fuel mixture.

6.0 DISCUSSION 6.1 Problems and Solutions on the cylinder head

6.1.1 Gasket failure

Overheating, a result of coolant leak, bad thermostat, or cooling fan failure, is

frequently the leading cause of head gasket failure. To specify, many cars today use
aluminum heads on cast iron blocks. Aluminum expands much faster than cast iron
which creates friction between the head and block. This will eventually cause it to leak
[1].

Figure 6: Gasket failure

Another reason for gasket failure is caused by detonation. An abrupt increase in

combustion chamber pressure brought on by detonation might eventually overburden
and crack the gasket armor encasing the cylinder as shown in the picture below. A
reason for this is a buildup of carbon that raises compression in the combustion
chamber. If the fuel ignites on its own due to excessive compression before the spark
can set it off, the engine will knock.
 Figure 7: Detonation damage

Solution
1. Loosen all the bolts and remove the cylinder head.
2. Remove old gasket and any residue from the head and block using gasket
removal chemical and scrapper. Do not use equipment that can scratch the
surface.
3. Check the flatness using a feeler gauge and straight edge of head and block. If
it is not flat, the surface needs to be machined until smooth.
4. Pre-fit the gasket in the correct orientation. Only use sealant if required by the
manufacturer.
5. Reassemble the head and block with the correct bolt tightening sequence to
ensure proper seal using the torque wrench.
6. Ensure that any potential contributing factors have been found and addressed in
order to prevent the replacement head gasket from suffering the same destiny as
the old one.

6.1.2 Cylinder Warpage

Cylinder head warpage refers to a cylinder head that has become sufficiently
deformed to prevent it from sealing and sitting in its proper position, which can lead
to leaks under your hood [2].
 Figure 8: Cylinder warpage

The main cause of this distortion in cars is overheating. Once the car starts, the cylinder
head is exposed to high temperature and expand and once the engine stops, the cylinder
head will cool down and shrink. This will happen multiple times and the head will take a
different shape eventually.

Solution:

1. Loosen all the bolts and remove the cylinder head.

2. Check how much the cylinder head warp using a feeler gauge and straight edge.
3. Place bolts in the center of the head and place washers and nuts on the bottom of
the head and tighten it up.
4. Place the head in the oven for a few hours and let it cool down.
5. Check the topside of the head for straightness. The previous step may need to be
repeated a few times until straight.
6. Once the topside is perfect, the bottom side might be a little warp but can be
machined until straight.

6.1.3 Cylinder head cracked

 Some cylinder heads may develop cracks due to design flaws. But in most cases,
the problems occur in result of engine overheating. When the engine gets too hot,
the cylinder head can stress because of thermal stress. Allowing engine to overheat
once and it can result in a cracked cylinder head.

Figure 9: Cracked cylinder head

A crack in the cylinder head can allow coolant from the coolant passages to leak
into the engine’s combustion chamber. As a result, white smoke will be coming out
of the vehicle’s tailpipe [3].

Solution:

The most used technique for repairing cracks is by doing pinning. Pinning is
fast, reliable, and cheap. Pinning is a relatively easy technique to learn and use as it
doesn’t require any special tools other than a drill, guide fixture and tap. The
technique involves drilling holes in both ends of the crack to keep it from spreading,
then drilling holes at various intervals along the length of the crack. Then it needs
to install overlapping pins to fill the crack then peening over the pins with an air
hammer to seal and blend the surface [4].

6.1.4 Valve

Some of the sign that the car has a valve failure are ticking or popping noises.
The noise will get louder and faster as the engine accelerated. It usually means that
some of the valve train components are either worn out or out of alignment or the
 engine is not getting enough lubrication. Other symptoms that can be visible is blue
smoke from the tailpipe [5].

Figure 10: Misalign valve

Solution:

1. Draining the oil and coolant 2.

Removing the cylinder head parts
3. Removing all head bolts.
4. Lifting the cylinder head from the engine.
5. Remove the valve cover.
6. Remove the stud-mounted rocker arm and pushrod (if used).
7. On OHV, remove the shaft assembly and pushrods, if used. On OHC
engines, remove the camshaft.
8. Use a valve-spring compressor and remove the valves and spring from the
head.
9. Inspect the valves, valve seats and valve guide and service, as necessary.

7.0 CONCLUSION

In conclusion, students can identify the components found on the cylinder head and understand
their function. Students can perform a practical on how to tighten the bolts on the cylinder
head. Furthermore, students can learn how to install bolts in a specific sequence, of which there
are two. Begin with the bolt in the middle and work your way out. It can also aid students'
comprehension of the presentation and help them improve their communication skills.
References

[1] L. Carley, “Uncovering the Causes of Head Gasket Failure,” Tire Review Magazine,
May 03, 2011. [Online]. Available: https://www.tirereview.com/uncovering-
thecauses-of-head-gasket-failure/. [Accessed: Dec. 21, 2022]
[2] C. C. Heads, “What Is Cylinder Head Warpage and What Causes It?,” Clearwater
Cylinder Head, Dec. 08, 2020. [Online]. Available:
https://www.cylinderheads.com/cylinder-head-warpage/. [Accessed: Dec. 21, 2022]
[3] “The Top 7 Symptoms of a Cracked Cylinder Head - In The Garage with
CarParts.com,” In The Garage with CarParts.com, Apr. 07, 2021.
https://www.carparts.com/blog/the-top-7-symptoms-of-a-cracked-cylinder-head/
(accessed Dec. 21, 2022).
[4] L. Carley, “Cracked Cylinder Head Repair,” Engine Builder Magazine, Jan. 05, 2012.
 https://www.enginebuildermag.com/2012/01/cylinder-head-repair-methods/ (accessed
Dec. 21, 2022).
[5] MegaAdmin, “Three Signs Your Car Has a Valve Problem - White’s Automotive
Center,” White’s Automotive Center, Jan. 13, 2022.
https://whitesautomotive.com/three-signs-your-car-has-a-valve-problem/ (accessed
Dec. 21, 2022).
S. M, Nili, Buster, M. Anthony, and J. chomba, “Cylinder head: Diagram, parts,
function, types, uses [PDF],” The Engineers Post, 02-Aug-2021. [Online]. Available:
https://www.theengineerspost.com/cylinder-head/. [Accessed: 21-Dec-2022].