GUJARAT TECHNOLOGICAL

UNIVERSITY

L.D. COLLEGE OF ENGINEERING,

AHMEDABAD.

M. E. (I. C. E. & AUTO.)

SEMESTER 2nd
YEAR 2015 - 16.
Unit 1 : Engine
Maintenance

Prepared By: A. G Parikh (150280711001)

Sagar Babariya (150280711001)

Engine Maintenance is broadly of three
types:
Scheduled Maintenance (Routine Maintenance)
This type is also a preventive maintenance which
includesinspections, and part replacements that vehicle
manufacturer recommends based on the age or mileage of
vehicle. With regular maintenance to replace worn parts,
engine can continue to run smoothly and we can avoid
costly engine repairs of break down.

Engine Tune up
If engine feels sluggish, lacks power, some times misfires or
runs rough, A tune-up is typically done every 60,000-90,000
miles and to ensure smooth drivability. A tune up activities.
Prior to the advent of the electronic ignition, Engine Tune
up
Involved a lot of activities which now in a modern
automobile is merged with scheduled maintenance .
 Breakdown maintenance (Repair
maintenance)
Breakdown maintenance is done after sufficient
mileage life of engine running.
Or
Troubles starts appearing suddenly or due to poor
Preventive Maintenance.

Breakdown maintenance is of two kinds

1. Major overhaul
2. Minor or Top overhaul
It is connected with replacement of engine parts and
reconditioning.
 Scheduled Maintenance (Routine Maintenance)

Common car maintenance tasks include:

check/replace theengine oiland replaceoil filters
check/replacefuel filters
check, clean or replacebatteryterminals and top up battery fluid
check or flushbrake fluid
check or flushtransmission fluid
check or flushpower steering fluid
check and flush enginecoolant
inspect or replacespark plugs
inspect or replaceair filter
inspect or replacetiming beltand other belts
tighten chassis nuts and bolts
test electronics, e.g.,Anti-lock braking systemor ABS
read fault codesfrom theEngine control unit
 Engine Tune up

The term "Tune-up" is"general adjustment to

insure operation at peak efficiency
An in-depth tune-up today often requires the use
ofdiagnostic equipment
It helps to prevent excessive wear on the larger
components.
As a result, the car gets better gas mileage, and
the engine can continue to operate properly even
after several years of regular use.
With electronic ignition and electronic fuel
injection nearly eliminated the need for an engine
tune-up, they have eliminated most of the items
that tune-ups previously involved.
 Engine Tune up continued..
It most case it includes
Visual inspection of engine components
Installation of new spark plugs
Adjustment of timing and idle (if applicable)
Air filter replacement
Fuel filter replacement
PCV valve replacement
Fuel system service
Inspection and replacement of cables
Battery & Ignition system inspection.
Replacement of belts.
Breakdown maintenance (Repair maintenance)

Minor or Top overhaul includes all such engine

parts that can be replaced or repaired with
engine on the vehicle.
Removal of Engine Head for Reconditioning.
Replacement or Service of Valves assembly.
Removal of Cam shaft for service.
Removal of Pistons & Connecting rod for
replacement.
Replacement of Gaskets and oil seals.
Removal/Repair of Fuel system parts (Both
Petrol & Diesel)
Service of Emission Control Systems
 conti.. Breakdown maintenance (Repair
maintenance)

Major overhaul includes such engine parts for

which engine is to be removed from the
vehicle.

Removal Crankshaft for Reconditioning.

Removal of Cylinder Block for Reconditioning
Engine Troubles
The most common troubles that an engine will
have are 1. Poor Starting of Engine

Faulty Faulty Faulty Fuel Fault in

Starting Ignition System Engine
System
Cracked Head Gasket (Compression Leak)
Excessive Valve Clearance
Worn Valve timing Belt or Valves out of Time.
Poor Valve seating due to excessive carbon deposits ,
bent valve stem & Valve Pitting.
Excessive valve clearance.
Worn piston Rings
Engine oil too Viscous
Loose manifold or torn manifold gasket causing excess
air intake
Engine Troubles

2. Engine Cranks But does not start

Faulty Faulty Faulty Fuel Fault in

Starting Ignition System Engine
System Blown Head Gasket (Compression Leak)
Excessive Valve Clearance
Valves out of Time.
Poor Valve seating due to excessive carbon deposits ,
bent valve stem & Valve Pitting.
Excessive valve clearance.
Worn piston Rings, Cylinder wear
Loose manifold or torn manifold gasket causing excess
air intake
Continued Engine Troubles

3. Power loss & Poor Acceleration

Faulty Faulty Fuel Fault in

Ignition System Engine
Cracked Head Gasket (Compression Leak)
Excessive Valve Clearance
Worn Valve timing Belt or Valves out of Time.
Poor Valve seating due to excessive carbon deposits ,
bent valve stem & Valve Pitting.
Excessive valve clearance.
Worn piston Rings
Loose manifold or torn manifold gasket causing excess
air intake (lean mixture)
Poor Throttle control,
Clogged air Filter in diesel engine
Continued Engine Troubles

4. Excessive oil consumption

Oil leakage Oil pumping Faulty Valve stem

in C.C
Oil drain plug, Oil sump gasket, Leaky oil seals, Blown
cylinder head gasket, loose oil filter.

Worn piston Rings, ring grooves.

Worn or broken oil rings
Cylinder wear
Ring end gaps are not staggered.

Bent valve stem

Excessive clearance between stem & Guide
Continued Engine Troubles

5. Engine Over Heat

Faulty Cooling Faulty Lubrication Faulty Fuel & Faulty Ignition
System System Exhaust System
1. Not enough 1. Not enough oil. 1. Excessive Load 1. Improper
coolant. 2. Clogged oil and lean Ignition
2. Loose / filter, strainer. mixture. timing.
Broken Fan 3. Faulty oil pump. 2. Clogged 2. Faulty
Belt. 4. Poor or exhaust ports. temp
3. Faulty deteriorated 3. Clogged sensor.
Thermostat. quality of oil . Muffler. Other
4. Poor water 5. Oil pressure 4. Malfunctioning causes
pump. leakage from oil of intercooler 3. Dragging
5. Clogged seals. in diesel brakes.
radiator. engine. 4. Slipping
5. Late valve Clutch.
timings. 5. Bearing
to0 Tight.
Continued Engine Troubles

6. Excessive fuel consumption

Faulty Fuel Faulty Fuel system Engine Faults Faulty Driving
system (M.P.F.I) habbits
(Carburetor)
1. High float 1. Excessive Fuel 1. Excessive Load 1. Rash
level. pump pressure. or rolling Driving.
2. Fuel leak 2. Faulty Throttle resitance. 2. High speed
from pipe position sensor. 2. Faulty Valves driving.
joints. 3. Dribbling/ timing. 3. Short trips
3. Worn leaking injector. 4. Engine mis in low
carburetor 4. Faulty Oxygen firing gear.
body, sensor. 5. Blow by Losses 4. Improper
gasket. 5. Idle speed too Tyre
4. Clogged air fast. pressure.
vents. 5. Operating
5. Dirty air clutch and
cleaner. accelerato
6. Poor r together.
Continued Engine Troubles
7. Engine Backfires
Faulty in Engine
1. Over heated engine.
2. Carbon deposits in engine.
3. Valve hot or stuck.
4. Excessive lean mixture.
5. Faulty Anti backfire valves .
Faulty Ignition System
1. Improper Ignition timing.
2. Spark plug of wrong heat
range.
3. High tension leak in coil,
distributer, cap or rotor.
Continued Engine Troubles
8. Abnormal Engine Noise
Symptoms
1. Regular clicking
2. Light Knock or pounding
sound
3. Light double Knock audible
during idling.
4. Chattering during
acceleration
5. Hollow, muffled bell like
sound
6. Dull metallic knock under
load
Causes
1. Valve train
2. Noise due to worn Connecting rod
bearings, journal, misalign
connecting rod.
3. Worn or loose pin.
4. Worn or broken rings, worn cylinder
walls.
5. Piston slap due to excessive
clearance.
6. Noise due to main bearings and
thrust bearing.
7. Miscellaneous noise due to loose
mountings of alternator, water
pump etc.
Continued Engine Troubles

9. Poor Exhaust Emissions

Symptoms Causes

1. Blue Smoke 1. Excessive oil consumption.

2. Black Smoke 2. Excessively rich mixture.
3. White smoke 3. Poor quality fuel, steam in
exhaust, catalyst burning of residual
fuel due to poor air injection
system.
 Reconditioning of engine Parts
Valve Refacing and Valve seat Grinding.
Cylinder Boring and Honing
Crank shaft Grinding

After removal from the engine these parts are

inspected visually and dimensionally and then
reconditioned according to the exact
requirements and are finally assembled.