To be submitted for INSTRUCROR

ENGINE LABORATORY

LAB -1

 Different types of engines are given in the workshop, classify them using the
following parameters and justify by writing a report.

1. Number of cylinders
2. Arrangement of cylinders
3. Arrangement of valves
4. Type of cooling
5. Number of strokes per cycle (two or four)
6. Type of fuel used
7. Method of ignition (spark or compression)
8. Firing order
9. Reciprocating or rotary
10. OHV &OHC engines

LAB No 2

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 CHECKING CYLINDER BLOCK

Engine Type (model):________________________________

Use repair manual or consult the instructor for each specification

N.B:-Do not forget to write names of groups at the back of the page

1. Measuring (Checking) Warpage

2. Checking main bearing bore alignment

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  Extend the straightedge across the main bearing saddle bores.
 Try to slip a thickness gauge under the straightedge at each main saddle location.

Standard value __________

Conclusion:-

3. Checking Main Bearing Bore Diameter and Out of Roundness (see your text page
197 7 198)

4. Cylinder bore diameter

Adjustment of the Bore Gage

MEASURING THE CYLINDER BORE

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Operation:

 Measure the cylinder with a caliper, round up

the
measured result to the next full millimeter.
 Adjust the micrometer exactly according to this
rounded-up value.
 Transfer the value of the micrometer to the
dial gage mounted in the measuring device
(scale 0 to the pointer in the point of return).
 Bring the measuring device into the cylinder
and search for the point of return.
 Read and write down in the table the diameter
parallel to the piston pin.
 Read and write down in the table the diameter
perpendicular to the piston pin.

Findings
Nr. Measuring Point
"A" "B"
1 TDC, height of 1st ring
2 BDC, height of 1st ring
3 Bottom of cylinder

Standard cylinder bore _________________________

Given the following Formulas

• Max Taper = Maximum measurement - Standard cylinder bore

• Max Wear=Maximum measurement-Standard cylinder bore
• Out-of-round = Y - X

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LAB No 3
CHECKING CRANKSHAFT

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 1. Crankshaft runout (crank pin)

Standard ______________

Measurement ____________

Conclusion:-

2. Out-of-roundness ((crank pin)

 Out-of-round = X - Y

3. [Link] ((crank pin)

 Taper = A - B

No. 1 X Y Out-of-round No. 2 X Y Out-of-round

A A
B B
Taper Taper

Max. Taper ______________ mm Max. Taper _________ mm

Max. Out-of-round ___________ mm Max. Out-of-round _______ mm

No. 3 X Y Out-of-round No. 4 X Y Out-of-round

A A
B B
Taper Taper

Max. Taper ______________ mm Max. Taper _________ mm

Max. Out-of-round ___________ mm Max. Out-of-round _______ mm

No. 5 X Y Out-of-round No. 6 X Y Out-of-round

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 A A
B B
Taper Taper

Max. Taper ______________ mm Max. Taper _________ mm

Max. Out-of-round ___________ mm Max. Out-of-round _______ mm

*limit ( Taper ) ______________ mm

*limit ( Out-of-round )______________ mm
Conclusion:-

3. ii. Taperness (main journal)

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 No. 1 X Y Out-of-round No. 2 X Y Out-of-round
A A
B B
Taper Taper

Max. Taper ______________ mm Max. Taper _________ mm

Max. Out-of-round ___________ mm Max. Out-of-round _______ mm

No. 3 X Y Out-of-round No. 4 X Y Out-of-round

A A
B B
Taper Taper

Max. Taper ______________ mm Max. Taper _________ mm

Max. Out-of-round ___________ mm Max. Out-of-round _______ mm

No. 5 X Y Out-of-round No. 6 X Y Out-of-round

A A
B B
Taper Taper

Max. Taper ______________ mm Max. Taper _________ mm

Max. Out-of-round ___________ mm Max. Out-of-round _______ mm

*limit ( Taper ) ______________ mm

*limit ( Out-of-round )____________ mm

Conclusion:-

4. i. Crankshaft main bearing oil clearance (plastigage method)

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 1 2 3 4 5 6

*limit ______________ mm

Conclusion:-

ii. Connecting rod bearing oil clearance

1 2 3 4 5 6

*limit ______________ mm

Conclusion: -

5. Crankshaft thrust clearance

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Measurement _______________ mm

* Limit ______________ mm
Conclusion:-

LAB No 4

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CHECKING PISTON DIAMETER, RING END GAP, RING GROOVE CLEARANCE
& PISTON TO CYLINDER OIL CLEARANCE

 Piston diameter

1 2 3 4 5 6

*limit ______________ mm
 Piston ring end gap

1 2 3 4 5 6
Top
Second
Oil

*limit
Top ______________ mm
Second ______________ mm

 Piston ring groove clearance

1 2 3 4 5 6
Top
Second

*limit
Top ______________ mm
Second ______________ mm
 Piston to cylinder oil clearance

1 2 3 4 5 6
Max [Link]
Piston dia
Oil clearance
Conclusion:-

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LAB No 5
CHECKING CONNECTING ROD BEND & TWIST

 Connecting rod alignment (Bend and Twist)

1 2 3 4 5 6
Twist
Bend

* limit
Twist ______________ mm
Bend ______________ mm
Conclusion:-

LAB No 6

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CAMSHAFT CIRCLE RUNOUT, JOURNAL DIAMETER, CAM LOBE HEIGHT

 Camshaft circle runout

measurement ______________(mm)

* limit ______________(mm)
Conclusion:-

 Cam lobe height

1 2 3 4 5 6
Intake
Exhaust

* limit IN______________(mm)
EX______________(mm)
Conclusion:-

LAB No 7

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CHECKING CYLINDER HEAD WARPAGE

Measurement _______________(mm)

*Limit ______________(mm)
Conclusion:-

LAB No 7

VALVE OIL CLEARANCE, STEM DIAMETER, BENDING, MARGIN THICKNESS, OVERALL

LENGTH

 Oil clearance

1 2 3 4 5 6
IN.
EX.

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 *Oil clearance limit:

IN. __________________(mm)

EX. __________________(mm)
 Valve stem diameter

1 2 3 4 5 6
In. min.
In. max.
Ex. min.
Ex. max.

 Valve bending
1 2 3 4 5 6
Intake
Exhaust

 Head margin thickness

1 2 3 4 5 6
Intake
Exhaust

 Overall length
1 2 3 4 5 6
Intake
Exhaust

 Valve contacting position and width

1 2 3 4 5 6
Intake
Exhaust

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  Valve seat contacting position and width
1 2 3 4 5 6
Intake
Exhaust

 Valve spring installed length

1 2 3 4 5 6
Intake
Exhaust

 Valve spring squareness

1 2 3 4 5 6
Intake
Exhaust

 Valve spring free length

1 2 3 4 5 6
Intake
Exhaust

 Valve spring load

1 2 3 4 5 6
Intake
Exhaust

 Valve face angle

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 1 2 3 4 5 6
Intake
Exhaust

Conclusion:-

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