THIKA TECHNICAL TRAINING COLLEGE

MECHANICAL ENGINEERING DEPARTMENT

AUTOMOTIVE SECTION
ENGINES TECHNOLOGY PRACTICE
JOB SHEET 2
TITLE: ENGINE OVERHAUL
AIM: TO DISMANTLE THE CYLINDER HEAD AND THE ENGINE BLOCK AND CLEAN
COMPONENTS FOR INSPECTION AND REPAIR.
Tools materials and equipment
 General toolset
 Valve spring tool
 Dot punch
 Trays
 Hammer
 Torque wrench
 Decarbonizing brush
 Internal combustion engine
 Soft brush
 Cleaning solvent (kerosene)

 Waste rugs

Safety considerations
1. Personal protective equipment is a must
2. Safety is a personal responsibility
3. Be careful when lifting heavy objects to prevent musculoskeletal injuries
4. Place the heavy objects on the bench squarely on the bench and confirm they are stable
5. Do not aim a compressed air gun at any part of your body or at your colleague.
6. Be cautious of any oil spills. Address the oil spills immediately after they occur
7. Follow the standard operating procedure as given by technical manuals
8. Use the correct tool for the correct job to avoid injuries.
9. Report any hazards or injuries to the trainer.
Preparation
 Gather all the tools required and prepare a working surface
 Prepare drain trays to avoid spills
Procedure-
Dismantling the cylinder head
1. Mark all valves with respective cylinder numbers with a dot punch
2. Compress the valve spring with a valve spring tool and remove the collets, store carefully
3. Remove the valves
4. Remove the valve seals
5. Inspect the valves, the valve seats, the valve guides and the cylinder head face
6. Clean all parts in preparation for repair
Dismantling the block
1. Place the block in an appropriate position
2. Remove the attachments from the engine
3. Remove the oil sump and oil pump
4. Slacken connecting rod bolts and remove the pistons
5. Remove the timing case
6. Inspect the camshaft drive timing marks
7. Remove the timing gears, belts or chain
8. Remove the camshaft and injector pump
9. Remove the timing backplate
10. Slacken the crankshaft caps in order
11. Remove the crankshaft and place it on the bench
12. Remove the oil throwers
Cleaning all components
1. Clean all components with a suitable solvent starting with the less dirty ones
2. Sort the components ready for inspection