GCUF layyah campus.

1. Engine SERVICEEngine SERVICE
AND OverhaulingAND Overhauling

2. What is serviceWhat is service
 A A motormotor vehicle vehicle serviceservice is a series of is a series of
maintenance procedures carried out at a set timemaintenance procedures carried out at a set time
interval or after the vehicle has travelled ainterval or after the vehicle has travelled a
certain distance.certain distance.

3. What is overhaulingWhat is overhauling
 An engine overhaul is a comprehensive engineAn engine overhaul is a comprehensive engine
tune-up that involves removing andtune-up that involves removing and
disassembling a vehicle's engine, testing all thedisassembling a vehicle's engine, testing all the
components, cleaning and replacing parts ascomponents, cleaning and replacing parts as
needed and then reassembling the engine. This isneeded and then reassembling the engine. This is
done to improve vehicle performance anddone to improve vehicle performance and
prolong the life of the engine.prolong the life of the engine.

4. Tools and Equipment used in EngineTools and Equipment used in Engine
OverhaulingOverhauling
Mainly, Two Kinds of Overhauling ToolsMainly, Two Kinds of Overhauling Tools
 Testing ToolsTesting Tools
 Servicing ToolsServicing Tools
1.Servicing Tools :1.Servicing Tools :
 Nozzle CleanerNozzle Cleaner
 Valve Seat GrinderValve Seat Grinder
 Valve Guide Knurling ToolsValve Guide Knurling Tools

5. Tools and Equipment used inTools and Equipment used in
Engine OverhaulingEngine Overhauling
 Valve Spring CompressorValve Spring Compressor
 Valve Guide ReamerValve Guide Reamer
 Cylinder Ridge ReamerCylinder Ridge Reamer
 Cylinder Reboring BarCylinder Reboring Bar
 Piston Knurling ToolsPiston Knurling Tools
 Piston Ring ExpanderPiston Ring Expander

6. Tools and Equipment used inTools and Equipment used in
Engine OverhaulingEngine Overhauling
 Piston Ring CompressorPiston Ring Compressor
 Piston Ring Grove Cleaning MachinePiston Ring Grove Cleaning Machine
 Piston and rod Aligning ToolsPiston and rod Aligning Tools
 Screw DriverScrew Driver
 HammerHammer
 Stud RemoverStud Remover
 Injection Nozzle Remover ToolsInjection Nozzle Remover Tools

7. Tools and Equipment used inTools and Equipment used in
Engine OverhaulingEngine Overhauling
2.Testing tools2.Testing tools
 Filler GaugeFiller Gauge
 Depth GaugeDepth Gauge
 Dial GaugeDial Gauge
 Limit GaugeLimit Gauge
 Height GaugeHeight Gauge
 Hole GaugeHole Gauge
 Radius and Fillet GaugeRadius and Fillet Gauge

8. Tools and Equipment used inTools and Equipment used in
Engine OverhaulingEngine Overhauling
 Measuring Tools:Measuring Tools:
 Steel ScaleSteel Scale
 MicrometersMicrometers
 CallipersCallipers
 Slide CallipersSlide Callipers
 Hook RuleHook Rule
 DividersDividers

9. Process of engine overhaulingProcess of engine overhauling
and servicingand servicing

10. Remove EngineRemove Engine
Place engine securely on an engine stand

11. Remove AccessoriesRemove Accessories

12. Remove Intake and Valve trainRemove Intake and Valve train
ComponentsComponents

13. Remover Cylinder HeadsRemover Cylinder Heads
Remove the head bolts. Check for damage especially
between cylinders

14. Remove all RidgesRemove all Ridges
Two wrenches opposite of each other give you good control

15. Remove Oil Pan and InspectRemove Oil Pan and Inspect

16. Remove Gaskets and Scrape AwayRemove Gaskets and Scrape Away
CrudCrud

17. Remove Front CoverRemove Front Cover

18. Remove Pistons and Main CapsRemove Pistons and Main Caps

19. Remove Crank and CamshaftRemove Crank and Camshaft

20. Remove Camshaft BearingsRemove Camshaft Bearings
You need a specific tool for this– clean out all bolt holes with a tap

21. Clean the Internal AreaClean the Internal Area

22. Inspect Cylinder headsInspect Cylinder heads

23. Cracks- You Don’t Want To See ThisCracks- You Don’t Want To See This

24. Clean the HeadsClean the Heads

25. Spring Tool and Valve ToolSpring Tool and Valve Tool
You will need to measure spring
Tension and height

26. Cylinder Head DisassemblyCylinder Head Disassembly

27. Inspect Valve, Springs, and RotatorInspect Valve, Springs, and Rotator

28. Inspect For CracksInspect For Cracks
Check Here

29. Valve GrindingValve Grinding
This resurfaces the
valve angle

30. Cut & Check Valve SeatCut & Check Valve Seat

31. Valve seat AnglesValve seat Angles
Seat
45 degrees
15 degrees
60 degrees

32. Clean and Inspect PistonsClean and Inspect Pistons

33. Clean and Inspect the Entire EngineClean and Inspect the Entire Engine

34. Preparation for PaintingPreparation for Painting

35. Paint HeadsPaint Heads
Cover valve area and block ports

36. Paint BlockPaint Block
Cover internal parts, you don’t need to paint where the oil will be, use high heat paint

37. Measure, Measure, MeasureMeasure, Measure, Measure

38. Install CamshaftInstall Camshaft
Take care with the cam and it’s bearings when installing. Over lube this as you install.

39. Measure Ring GapMeasure Ring Gap
This gap needs to be precise, file the gap to specs

40. Install and Bolt Main CapsInstall and Bolt Main Caps
You will want to confirm the inside diameter is correct and round

41. Bolt and Torque CrankBolt and Torque Crank

42. Fit the RingFit the Ring

43. Lube the Rod BearingsLube the Rod Bearings
Oil the rings
Use engine oil

44. Prep Pistons for InstallationPrep Pistons for Installation

45. Install PistonsInstall Pistons

46. Installing Timing ChainInstalling Timing Chain

47. Clean and Prep the Cylinder HeadsClean and Prep the Cylinder Heads

48. Bolt and Torque the HeadsBolt and Torque the Heads

49. Prepare the Front CoverPrepare the Front Cover
Check the timing marks again just to make sure. Use a little extra sealer in the corners.

50. Install Front CoverInstall Front Cover

51. Install Harmonic BalancerInstall Harmonic Balancer
blancer

52. Prep For Intake ManifoldPrep For Intake Manifold
Use a good sealer here to help the intake seal. Take care to keep gasket aligned

53. Place the GasketsPlace the Gaskets

54. Install intake and DistributorInstall intake and Distributor

55. Install Oil Pump and FilterInstall Oil Pump and Filter

56. Wires NowWires Now

57. Install Oil PanInstall Oil Pan
Use a good
sealant here
Install a fuel
pump also

58. Install AccessoriesInstall Accessories
Valve covers
Exhaust manifolds
Water pump
Carburetor

59. Advantages of Engine service andAdvantages of Engine service and
overhaulingoverhauling
 No sudden engine stopsNo sudden engine stops
 No time lossNo time loss
 Effective cost controlEffective cost control
 Perfect overhauling engine works more perfectPerfect overhauling engine works more perfect

61. Group MemberGroup Member
 Shahid Akram Roll No. 885Shahid Akram Roll No. 885
 Azmul Hassan Roll No. 881Azmul Hassan Roll No. 881
 Basid Roll No. 882Basid Roll No. 882
 M.Hamza Roll No. 858M.Hamza Roll No. 858