OVERHAULING OF FUEL INJECTION PUMP (PNEUMATIC TYPE)
Contents
1. CAV pump has 3 nuts and one bolt while Mico Bosch pump has 2 nuts and one bolt 19 Mounted pump at its specified place over timing plate and adjusted it Brought pump timing mark and timing plate mark in front of each other and threaded all three nut and bolt along with washers Tightened them using 12mm and 13mm sized ring spanner and double ended spanner 20 Slightly tighten pump s main supply pipe and return pipe bolts with Pump Bleeded air from pipes and tighten the hand priming pump 21 Mounted F 1 Pump s timing gear and tighten slightly main nut Tighten nut over the 13mm bolt which was fitted in place of lock also tighten both bolts of plate mounted on main nut Fixed pump gear at specified space 22 Tighten high pressure pipes towards F I pump side however they kept loose from injectors end 23 Re installed solenoid switch s connection and connected accelerator wire with F I pump 24 Mounted timing belt over F I pump gear and cam shaft gear and adjusted timing with idler Tighten idler bolt properly 25 Unthreaded both bolts of 13mm from cam shaft gear and F I P gear Unlocked flywheel by taking out alien key 26 Rotated two or three revolutions of crank shaft with the help of ring spanner There should not be any noise etc 27 Started the engine and bleed air from injector holders which were kept loose Tighten them after bleeding Note do not apply heater while doing a2. li Dismounted base plate from pump 12 Clean and check all components found that plungers were defective Checked taper roller bearing of Cam shaft it was not defective at all Note Assembly of plunger and barrel is called element 13 Mounted both side s taper roller bearings and the intermediate bearing and then the cam shaft in pump Adjust play 14 Placed control rod rack in F I pump and locked with its screw 15 Mounted tappets over cam shaft Automobile Engineering Practical 227 16 Mounted plunger plunger return spring regulating sleeve and upper washer above tappet assembly alreadymounted in fuel injection pump housing SEMESTER 4 DEISEL ENGINE SERVICE LAB 419 AUTOMOBILE ENGINEERING DEPT 17 Mount all plungers in same fashion above tappets and lock them 18 Adjusted element and placed delivery valve on its seat 19 Mount washer spring and peg Rubber sealing ring and holder over delivery valve and tighten the holder using a socket 11 16 20 Placed lock over holder neck and tighten it 21 Mounted toothed quadrant by the side of control rod and Pump housing Checked governor assembly and found it OK 22 Replaced inlet and outlet valves of feed pump Checked piston and outlet pressure of feed pump which was found to be up to mark 23 Mounted and tightened feed pump over cam 24 Mounted front plate Connected flange to cam shaft of F I Pump and locked it with a nut 25
3. Y FEED PUMP ASSY HAND PRIMING PUMP FUEL INJECTION BODY 1 oy CONTROL GROVE 4 4 PLUNGER DRIVING FACE SPACING PLATE UPPER I S PLUNGER SPRING SPRING PLATE ADJUSTING NUT SCREW LOCK NUT TAPER ROLLER SEMESTER 4 DEISEL ENGINE SERVICE LAB 419 AUTOMOBILE ENGINEERING DEPT EXPERIMENT 2 OVERHAULING OF DISTRIBUTOR TYPE FUEL INJECTION PUMP ROTARY PUMP LUCAS Objective Removing Getting Over Hauled Refitting Timing Setting and Bleeding of Air Tools and Equipment Used Double Ended Spanner Set mm Ring Spanner Set mm Allen Key 7 mm Flat Screwdriver Raw Material required 13 mm bolts 2 No s of 1 5 to 2 length Old Dhoti Procedure 1 Dismount the pump from vehicle due to loss in average 2 Dismounted air cleaner 3 Timing cover was splatted in two pieces took out first piece with the help of screwdriver and to remove its second piece loosen alternator s foundation bolts followed by their unthreading and taking out clamp To loosen bolts we used 16 17 mm sized ring and double end spanner 4 Bring gear lever in neutral position before dismounting pump 5 Disconnected battery connections 6 Dismounted accelerator cable from F I pump 7 Unthreaded banjo bolts of main fuel supply line and return fuel pipe line from pump 8 If crank is rotated by two revolutions cam shaft rotates by one only If cam shaft s tim
4. 4 Inspection I Checked unevenness of cylinder head by placing it on surface plate ii Checked scratch marks etc iii Checked pitting marks on valves and their seats iv Applied emery paste on pitting marks and grind using valve grinding stick Note if valve guide or valve seat is worn out or the valves are worn out Replace all y Checked injector for pressure and dribbling If nozzle holes are blocked clogged they should be cleaned with the help of cleaning kit Note New injector s pressure 175 kg sq cm Old injector s pressure 160 kg sq cm If pressure is less than 150 kg sq cm Overhaul injector 5 Assembly Fitted all valves in heads ii Mounted cylinder head with new gasket iii Tighten all cylinder head nuts with a tightening torque of 15 gm or 110 lb ft iv Mounted rocker assembly and push rod y Mounted all injector and their leak off pipe SEMESTER 4 DEISEL ENGINE SERVICE LAB 419 AUTOMOBILE ENGINEERING DEPT vi Re installed connections of exhaust and inlet manifold fuel lines air compressor water pump radiator hose and temperature gauge vii Adjusted tappet clearance In cold condition O 5m 0 020 viii Filled radiator with coolant ix Air bleed high pressure pipe lines x Fitted tappet cover with packing on it xi Checked engine oil s level xii Re installed battery connections and started the engine xiii Checked engine on high low and idle spe
5. CONNECTING ROD BUSH FIT ANOTHER CIRCLIP ON THE GROOVE HOLD TE ISTON RING IN THE RING EXPANDER AND FIT IT IN THE PISTON GROOVE ENSURE THAT THE WORD TOP STAMPED ON THE RING FACE UPWARD FIT ALL THE RINGS TO ALL THE PISTONS e PLACE THE UPPER AND LOWER BEARING SHELLS IN THE CONNECTING RODS AND CAPS AND KEEP THEM IN PROPER ORDER FOR REASSEMBLING PURPOSE SEMESTER 4 DEISEL ENGINE SERVICE LAB 419 AUTOMOBILE ENGINEERING DEPT UPPER LOWER COMPRESSION COMPRESSION RING RING OIL RING ASSEMBLY 6108 6148 PISTON PISTON PIN 6135 CONNECTING ROD BOLT 6214 BEARING INSERTS CAP NUT 6212 FM SEMESTER 4 DEISEL ENGINE SERVICE LAB 419 AUTOMOBILE ENGINEERING DEPT EXPERIMENT 12 BLEEDING THE FUEL SYSTEM IN DIESEL ENGINE OBJECTIVES BLEED THE FUEL SYSTEM IN A DIESEL ENGINE JOB SEQUENCE LOOSEN THE BLEEDING SCREW AT THE FUEL FILTER BY TWO TURNS TO ALLOW THE AIR TO ESCAPE THROUGH THE HOLE IN THE BLEEDING SCREW PUMP THE FUEL BY THE HANDPRIMER IN THE FEED PUMP TILL THE FUEL FLOWS THROUGH THE BLEEDING SCREW VENT HOLE WITHOUT AIR TIGHTEN THE BLEEDING SCREW AGAIN REPEAT THE OPERATION TILL THE AIR IN THE SYSTEM IS FULLY DRAWN OUT LOOSEN THE BLEEDING SCREW AT BY ONE OR TWO TURNS SO THAT AIR CAN ESCAPE THROUGH THE HOLE FROM THE BLEEDING SCREW TIGHTEN THE BLEEDING SCREW AGAIN REPEAT THE OPEARATION TILL THE AIR IN THE SYSTEM IS FULLY DRIVEN OUT SEMESTER 4
6. LO Overhauling engine block crankshaft and camshaft Objectives Descale water jacket s passages Clean the engine block Check the engine blocks for cracks Check the machines surface s of the block for burrs and scores Check the parent bore for In line alignment Remove the liners Fit the liners Inspect the flywheel and ring gear Inspect the crank shaft journal and crank pin Inspect the cam shaft for bend and twist Inspect the cam lob and measure the cam lob lift Inspect the cam shaft journals and bearings Inspect the cam shaft bearings and sprockets and tensioners Assemble all the above engine parts Job sequence e Cleaning and checking engine parts and place the engine block on wooden pieces e Clean the cylinder block with a suitable solvent or in degreasing equipment f available e Clean the oil passages remove al sludges dirt and carbon deposits in the cylinder blocks Use a scraper to remove hard deposits Ensure that the highly finished surfaces are not damaged Examine the surface and check for damage e Remove the Welch plugs Descale the water passages with pressurized water with a suitable solvent under high pressure Fix new plugs e Clean and dry the block by using compressed air e Clean the crankshaft using a soft brush with the recommended cleaning solvent e Clean sludge and gum deposits from the drilled oil passages in the crankshaft with a wire e Blow out the passages with compressed air e Check
7. Set inch Ring Spanner Set inch Socket Set inch Feeler Gauge mm Steel Foot Rule 12 Raw Material Required Cotton Waste Engine Oil Gasket Shellac Kerosene Oil 192 Automobile Engineering Practical Procedure 1 Drained out engine oil from engine by unplugging drain plug with the help of double ended spanner 2 Dismounted oil sump from engine by unthreading all bolts of oil sump 3 Dismounted oil pump by unthreading foundation bolts 4 Cleaned oil pump and took out oil strainer 5 Unthreaded upper plate and took out driven gear Cleaned all components 6 Checked back lash between driver and driven gear with the help of feeler gauge also measured side clearance Back lash found to be 0 15mm 7 Measured side clearance found to be OK 8 Placed steel foot rule over body and gear checked clearance found to be OK 9 Placed upper plate and tighten all bolts mounted oil strainer with gasket over oil pump 10 Immersed oil pump in an engine oil filled tray 11 Rotated driven gear so the pump sucked the oil and checked its pressure 12 Mounted pump with gasket in engine block and tighten all nuts 13 Mounted oil sump with gasket to engine block Tighten drain key 14 Filled SAE 20W40 grade of engine oil through filler plug provided in tappet cover and up to maximum mark given on dipstick 15 Started engine and checked oil pressure Precautions 1 Oil sump should be cleaned before mounting
8. DEISEL ENGINE SERVICE LAB 419 AUTOMOBILE ENGINEERING DEPT EXPERIMENT 1 OVERHAULING OF FUEL INJECTION PUMP PNEUMATIC TYPE Objective Removing Dismantling Cleaning Checking Assembling Testing and Refitting Tools and Equipment Used Double ended Spanner Set inch Ring Spanner Set inch Flat Screw Driver 6 amp 10 Tray Swan Neck Pipe Spill Cut off Pipe Socket Set inch Hammer 2 2 pounds Raw Materials diesel cotton waste brush engine oil Procedure 1 Disconnected fuel pipe line from fuel pump s inlet and outlet from El pump s gallery 2 Disconnected high pressure pipe from holder and injector and also disconnected vacuum pipe and Engine stopping wire 3 Dismounted Fl pump by unthread its bolts from foundation of engine block and coupling 4 Wash and clean FI Pump assembly with diesel 5 Dismounted inspection plate and checked control rack 6 Dismantled governor cover and disconnected diaphragm from control rod 7 Unthreaded nuts of flange coupling and dismantled it from control rod 8 Took out delivery valve from dismantled holder and pulled out plunger assembly by dismantling lower plate lock Repeated the same procedure for rest of all plungers Took out tappets also 9 Brought out the control rack after dismantling lock cap nut and control rack lock screw 10 Dismounted feed pump from F I Pump Dismantled front rear plates and the intermediate bearing brought out the cam shaft
9. ING BOLT CENTRE BOLT AIRVENT SCREW BLEEDING SCREW FILTER COVER ta N A Cc _ amp MICRO PAPER INSERT PREFILTER INSERT FILTER BOW Felt Filter Element Paper Filter Element Sectional View of Fuel Filter Assembly Stage 1 Stage ID Dismounting of Fuel Filter Bowls FELT FILTER CLEANING PLUGS Dismounting the Element a amp 5 Fixing Plug Dipping of Element into Diesel SEMESTER 4 DEISEL ENGINE SERVICE LAB 419 AUTOMOBILE ENGINEERING DEPT EXPERIMENT 8 Draining amp refilling coolant RADIATOR Summary The objective of this procedure is to show you how to drain cooling system and refill with correct mixture of engine coolant Some vehicles have drain plugs on the side of the engine block The shop service manual will tell you if these need to be opened when draining the coolant Part 1 Preparation and safety Objective Drain cooling system and refill with correct mixture of engine coolant Personal safety Whenever you perform a task in the workshop you must use personal protective clothing and equipment that is appropriate for the task and which conforms to your local safety regulations and policies Among other items this may include Work clothing such as coveralls and steel capped footwear Eye protection such as safety glasses and face masks Ear protection such as earmuffs and earplugs Hand protection
10. MOVE THE PISTON BY HAND DONOT DROP ON THE FLOOR e REPEAT THE STEPS FOR ALL THE PISTONS CLEANING AND INSPECTION REMOVE THE CARBON DEPOSITS ON THE POISTON RING GROOVES USING SPECIAL TOOLS CLEAN THE PISTON PISTON RINGS AND THE CONNECTING ROD USING KEROSNE CHECK VISUALLYTHE PISTON SKIRT AND THE CROWN FOR SCUFFING CRACKS SCORING ETC CHECK VISUALY THE PISTON PIN CIRCLIP GROOVE AND THE PISTON FOR DAMAGE CHECK THE RING SIDE CLEARENCE IN THE RING GROVVES WITH FEELER GUAGE PLACE THE RING IN THE CYLINDER LINER WITHOUT THE PISTON AND MEASURE THE END GAP WITH A FEELER GUAGE PLCE THE PISTON IN THE LINER CYLINDER BORE AND MEASURE THE CLEARENCE BETWEEN THE LINER AND THE PISTON BELOW THE GUDGEON PIN WITH A FEELER GUAGE MEASURE TYH EPISTION DIAMETER AT DIIFERENT POINTS MEASURE THE CLEARENCE BETWEEN THE CRANK PIN AND CONNECTNG ROD S BIG END BEARING WITH A MICROMETER ND BORE DIAL GUAGE CHECK THE CONNECTING RODS SMALL END BUSH FOR WEAR AND SCORING CHECK THE CONNECTING RODS ALIGNMENT FOR BEND AND TWIST CHECK THE GUDGEON PIN SURFACE FOR ANY INJURY PLACE THE CONNECTING ROD ON THE ALIGNMENT FIXTURE ASSEMBILNG FIT ONE CIRCLIP IN THE GRROVE OF THE PISTON e ALIGN THE CONNECTING RODS SMALL END BORE AND THE GUDGEON PIN HOLE OF THE PISTON e TAP THE GUDGEON PIN INTO THE PPISTON PIN HOLE WITH THE HELP OF MALLET WHILE TAPPING KEEP THE SMALL END HOLE ALIGNED TO AVOID SEMESTER 4 DEISEL ENGINE SERVICE LAB 419 AUTOMOBILE ENGINEERING DEPT THE DAMAGE TO THE
11. Mounted side inspection cover with rubber gasket after filling the specified amount of lubricating in the pump 26 Fixed rear plate and mounted new diaphragm with controlling rod Fixed diaphragm spring properly and checked vacuum chamber Precautions 1 Phasing and calibration instructions of related manufacturer should be followed 2 After calibration all toothed quadrants should be tightened 3 Torn out diaphragm should be replaced 4 Slow running adjustments should be as per workshop manual 5 Plunger and barrel should be replaced simultaneously 6 If there is any play in cam shaft should be rectified 7 Control rack rod should be freely movable sliding and it should not be tight 8 After phasing tappets should be made check nut 9 Worn out plunger should not be used 10 Proper instructions relating to oiling of Pump should be followed 11 Feed pump valves should be installed properly and should be mounted carefully 12 Engine timing setting should be as per workshop manual 13 Clean diesel fuel should be supplied to F I pump 14 Do not work with dirty hands SEMESTER 4 DEISEL ENGINE SERVICE LAB 419 AUTOMOBILE ENGINEERING DEPT 15 Proper tools should be used DELIVERY VALVE HOLDER SEALING RING RUBBER PUMP GALLERY BLEEDER SCREW DELIVERY VALVE HOLDER LOCK DELIVER SSS SSS HIM CAV LA art Quo WSs SS qm N W x pm
12. ace out of the flywheel with the help of a dial indicator e Check the flywheel ring gear teeth for wear damage etc e Check the crankshaft visually for cracks and overheating e Check the crankshaft journals and crankpin for taper and ovality if the taper and ovality are more than the given limit then the crank shaft should be reground to the next undersize e Measure the oil clearance between the crankshaft main journal and the bearing shell e Check the fillet radii of the main and connecting rod journals e Check the run out of journals with a dial indicator If the run out exceeds the given limit then the crankshaft should be straightened e Recommend removal of the bend or replacement of the shaft if the maximum bend at any one of the places is foud morethan the limit specified by the manufacturer e Clean the cam shaft thoroughly e Inspect the cam shaft journals for scratches grooves and marks e Measure each journal for ovality taper and wear e Check the camshaft for bend and concentricity e Check the cam lobe surface for wear SEMESTER 4 DEISEL ENGINE SERVICE LAB 419 AUTOMOBILE ENGINEERING DEPT e Measure the base circle diameter of the cam lobe and the lobe height by a micrometer measure the lobe height The difference between the lobe height and the base circle dia is the cam lift replace the cam shaft if the cam lift found to be lessthan the specified limit e Check the oil pump drive gear for pitting wear and dam
13. age if any e Check the cams eccentricity for the fuel pump drive e Measure the clearance between the thrust washer and the camshaft s first journal e Measure the end play of the cam shaft with the help of a dial indicator e Change the thrust washer if the end play is not asper the manufacturer s recommendation e Inspect the teeth of the sprocket for chain drive e Check the chain for elongation for chain drive e Check the teeth of the timing gear for gear drive e Check the pully and belt for cracks damage etc e Check the belt tensioner for chain drive ASSEMBLING e Clean the parent bore of the main bearing in the cylinder block e Clean the oil holes of the parent bore e Place the maim bearing shell into its respective parent bore Ensure that the oil hole of the bearing shell and that of the parent bore align e Install the crank shaft rear bearing seal oil seal e Insert the rubber packing rubber rod in the holes between the bearing cap and the cylinder block e projection of the rubber packing should not be morethan 6mm if it is morethan 6 mm cut off the excess length e Install the thrust washers into the respective bearings e Lubricate all the bearing surface with clean engine oil e Place crankshaft in its position in the cylinderblock e Place the shell bearing into their respective bearing caps e Checkthe bearing liners shells for spread The inserts should snap into position in the housin
14. anner Set mm Ring Spanner Set mm Long Nose Plier 6 Stud Plier Small Cleaning Tray Flat Screwdriver 9 Cleaning Brush 2 Raw Material Required Diesel Old Dhoti Copper Washer Kit for Banjo Bolts Small Container And Flexible Flue Pipe Procedure 1 Unthreaded banjo bolt 19mm which was threaded to main diesel line of feed pump with the help of ring spanner 2 Unthreaded outlet diesel line s bolt 19mm going up to diesel filters with the help of ring spanner 3 Unthreaded feed pump flange s nut 10mm and serrated feed pump from F I pump 4 Cleaned feed pump assembly by placing it in a small tray 5 Loosened clamping nut and serrated nylon filter and its housing from feed pump 6 Clamped feed pump lengthwise in bench vice with small wooden blocks as their packing 7 Loosened and dismounted hand priming pump Took out inlet valve and valve return spring from feed pump S Loosened and unthreaded outlet plug and took out outlet valve with valve return spring from feed pump 9 Unthreaded plug screw and took it out from feed pump body Also took out plunger return spring pump plunger pressure spindle from pump body 10 Took out tappet roller lock from lock groove with the help of nose plier 1l Serrated tappet roller assembly from feed pump 12 Serrated roller and pin from tappet roller assembly 13 Cleaned all components with diesel 14 Checked seats of inlet and exhaust valve bo
15. e through radiator ii Disconnected battery wires from terminals iii Unclamped water hoses iv Dismounted air cleaner y Took out inlet rubber hose pipe of air compressor from inlet manifold vi Dismounted fuel filters and fuel supply connections of injectors vii Dismounted injector pipes holding clamps from inlet manifold vii Dismounted exhaust pipe from exhaust manifold ix Disconnected temperature gauge x Loosened fan belt and dismounted water pump xi Unthreaded tappet cover bolts and took it out xii Took out leak off pipe from injectors and pulled out all injectors with the help of injector extractor xiii Dismounted rocker assembly and push rods xiv Unthreaded all nuts of cylinder head xv Dismounted cylinders head from engine SEMESTER 4 DEISEL ENGINE SERVICE LAB 419 AUTOMOBILE ENGINEERING DEPT xvi Took out head gasket from engine block xvii Serrated inlet and exhaust manifold 2 Dismantling of Cylinder Head j Numbered all valves from 1 to 12 using letter punch ii Compressed valve springs with the help of spring compressor and took out split cones collar seal and springs 3 Cleaning Scrapped off all the deposited carbon ii Decarbonize cylinder block also iii Cleaned cylinder head with the help of emery paper iv Thoroughly cleaned cylinder head by immersing it a tray filled with diesel or kerosene oil y Cleaned all passages of inlet and exhaust and all components
16. ed for leakage and noise xiv Engine s performance was up to the mark Precautions Head should kept precisely over wooden block avoid it from any scratch impression etc 2 Head gasket should be dry while fitting it No compound etc should be applied on it 3 Proper decarbonizing should be done to head and block 4 Cylinder head should be tightened in clockwise direction with specified torque 5 Worn out valve guides seats should be replaced 6 Properly tight fuel line connection and thoroughly checked for leakage etc 7 Less injector pressure should be adjusted followed by its fitment 8 Valves should be checked for locking etc using cotters 9 Ferrul O ring must be fitted for rocker lubrication while mounting head gasket SEMESTER 4 DEISEL ENGINE SERVICE LAB 419 AUTOMOBILE ENGINEERING DEPT OIL FILLER CAP Ged r OVERFLOW FUEL LINE FITTED ON INJECTOR T AR RACKER SHAFT 4 ROCKER COPPER WASHER poe mmm INJECTOR AOD SSA REA ORS gS MC AGN oNoQNONoN CYLINDER HEAD gt INLET VALVE CYLINGER HEAD GASKET SEMESTER 4 DEISEL ENGINE SERVICE LAB 419 AUTOMOBILE ENGINEERING DEPT EXPERIMENT 4 OVERHAULING OF FEED PUMP Objective Removing Dismantling Cleaning Checking Assembling Testing and Refitting Tools and Equipment Used Double Ended Sp
17. eed pump to it 14 Move hand priming pump up and down after installing feed pump and check pressure relief valve If it is not working jam the fuel line may damage SEMESTER 4 DEISEL ENGINE SERVICE LAB 419 AUTOMOBILE ENGINEERING DEPT HAND PRIMING PUMP WASHER PRESSURE SPINOLE FOR PUMP c g peu dilige LOCK RING lt INLET VALVE BANJO ROLLER OUTLET VALVE CRN lt BANJO BOLT COPPER WASHER SCREW PLUG ROLLER PIN gt am SPRING FOR PUMP PLUNGER PIN SCREW PLUG BANJO BOLT FILTER SLEEVE CLAMP NUT STUD lt CLIP SEMESTER 4 DEISEL ENGINE SERVICE LAB 419 AUTOMOBILE ENGINEERING DEPT EXPERIMENT 5 OVERHAULING OF ROTOR TYPE OIL PUMP Objective Removing Cleaning Checking Assembling and Refitting Tools and Equipment Used Double Ended Spanner Set inch Ring Spanner Set inch Feeler Gauge Steel Foot Rule Socket Set inch DRIVEN GEAR PUMP GASKET Raw Material Required Cotton Waste Engine Oil Gasket Kerosene Oil Shellac Procedure 1 Drained out engine oil form engine by unplugging drain plug with the help of double ended spanner 2 Dismounted oil sump from engine by unthreading all bolts of oil sump 3 Dismounted oil pump by unthreading all three bolts of it 4 Dismounted oil pump and took out its rotor assembly 5 Cleaned all components using kerosene oil 6 Placed inner and outer rotor in oil pump body 7 Checked clearance betwe
18. el line from diesel tank connected it with feed pump s inlet valve 5 Connected filter line with outlet of feed pump with banjo washer in the bolt 6 Moved priming pump up and down and as diesel starts coming out of outlet banjo bolt immediately tighten it with inlet of filter assembly 7 Bleed air from filter assembly through bleeding screws 8 Started the engine and varied its speed Engine was running properly with varying speed and it ensured us that feed pump is working properly Precautions I While working over feed pump cleanliness is important 2 Proper sized spanner should be used while dismantling and assembling priming pump outlet valve screw plug plunger screw plug 3 Do not overtight any screw plug of hand priming pump SEMESTER 4 DEISEL ENGINE SERVICE LAB 419 AUTOMOBILE ENGINEERING DEPT 4 Pump plungers O ring should be replaced while repairing it 5 Always use new rubber ring of filter housing 6 Never increase length of inlet and outlet valve return springs by pulling them 7 Replace inlet and outlet valve seats if they are pitted or worn 8 Worn out roller roller pin should be replaced 9 Fitment of pump plunger in bore should be checked with vacuum method If this fails replace both 10 Always new copper washers 11 Checked hand priming pump with vacuum method 12 Properly bleed fuel supply system after assembling 13 Fill pump s lubricating oil after fitting f
19. en both rotors with the help of feeler gauge Found it to be 0 003 8 Checked clearance between both the outer rotor and the body Found it to be 0 003 9 Placed foot rule over oil pump body and checked rotor s end surface which was 0 001 10 Mounted oil strainer and plate over oil pump body and tighten both bolts completely 11 Filled cleaning tray with fresh engine oil SAE 20 40 and immersed oil pump in it Mounted drive gearand rotated inner rotor so that pump sucked the oil 12 Further rotated drive gear and oil started coming out of outlet with pressure 13 Mounted oil pump with gasket on engine and tighten all three bolts 14 Filled four liter of fresh oil through tappet cover s filler plug 15 Started engine and checked engine oil pressure through pressure gauge Slow engine pressure was 1 5 kg Sq cm and on full throttle it was 4 5 kg sq cm Precautions 1 Inner and outer rotor clearance should not be more than 0 003 If it is more replace both 2 Clearance between outer rotor and oil pump body should be between 0 002 and 0 005 If it is more Replace outer rotor 3 Clearance between oil pump body and rotor end should not be more than 0 002 If clearance is more than oil strainer plate should be grind with emery paste and glass Set clearance 4 Oil pump should be filled with oil before mounting it SEMESTER 4 DEISEL ENGINE SERVICE LAB 419 AUTOMOBILE ENGINEERING DEPT 5 New packing should be instal
20. g and cap e Lubricate and install the bearing caps Ensure that the bearing caps are fitted in to their orginal positions e Hand tighten the main bearing cap bolts e Tighten the middle bearing to the specified torque and check the crankshaft for free rotation e Loosen the main bearing caps and bolts on one side check the gap between the main bearing cap and the cylinderblock surface with a feelergauge this gap indicates the bearing crush SEMESTER 4 DEISEL ENGINE SERVICE LAB 419 AUTOMOBILE ENGINEERING DEPT Tighten the bolts of the main bearing caps on either side of the centre bearing one by one to the specified torque Check the crankshaft for its free rotation after tightening each bearing cap s bolts Check the crankchaft end play To increase the end play use a thinner thrust washer and to reduce the end play use a thicker thrust washer Fit the ring gear on the flywheel Some manufacturers recommended to heat the ring gear up to a certain temperature before fitting heat expands the ring gear so that the ring gear can easily be fitted on the flywheel follow the manufacture s recommendation Align the flywheel dowel pins on the flange Install the flywheel on the crankshaft flange Lock the flywheel preventing it from rotation by using the special tool Tighten the flywheel mounting bolts nuts diagonally and evenly to the specified torque Clean and lubricate the camshaft bearings and journals and dis
21. ing gear and Pump s timing gear appears to be in locked position after one revolution then there is no need for second revolution 9 Used an Allen key of 7mm to lock flywheel 10 Rotate crank pulley or fan while locking flywheel 11 Rotate crank in clockwise direction 12 While rotating crank if alien key gets stuck in flywheel then slightly took out Allen key and revolve crank by 10 20 mm as there are two holes in lock position and if we fit alien key in second hole it gets stuck with flywheel and locks it 13 Piston no 1 and 4 will be on TDC cam and pump gear s lock position will be there 14 Threaded 13mm bolt to lock hole provided on F I Pump and cam gear and locked pump s gear by it 15 Loosen idler s bolt of timing belt and dismounted timing belt from cam and F I pump gears 16 Dismounted high pressure lines and separate them from F I pump and injector and disconnect solenoid switch connection SEMESTER 4 DEISEL ENGINE SERVICE LAB 419 AUTOMOBILE ENGINEERING DEPT 17 Loosened both bolts of 13mm which were threaded to plate mounted on F I pump Loosen F 1 Pump smain nut also Tighten both 13mm bolts again and further loosened main nut resultingF l pump s gear willcome out The main nut is threaded in center of plate having 13mm bolts 18 Took out all three foundation nuts and only bolt from timing plate along with washer Sent the pump to authorized dealer workshop to over it Note Lucas
22. ir bleeding 28 Knelt engine on running for approx 5 minutes and then stopped it for checking timing belt s tension If it is loose it should be tighten again 29 Again dismounted air filter and mounted upper piece of timing cover with the help of screwdriver and fitted clamp to the other piece for tightening it with alternator s bolt 30 Mounted air filter Precautions 1 First of all air filter should be dismounted otherwise it may create problem for timing cover 2 Alternator s bolt should be loosened before dismounting of timing cover 3 Battery connection should be disconnected as there is an alien key is to be fitted with flywheel SEMESTER 4 DEISEL ENGINE SERVICE LAB 419 AUTOMOBILE ENGINEERING DEPT Flywheel should be locked before dismounting F I pump 5 While locking F I P gear and cam gear bolts of 13mm and of length 1 5 2 should be used Smaller length bolts should not be used 6 While dismounting or mounting timing belt there should not be any foreign matter or lubricant etc on hands 7 While fitting or removing FTP Gear it should be kept locked with the help of 13mm bolt otherwise it will keep on rotating 8 While mounting F I pump on timing plate mark of plate and of pump should be in front of each other 9 Main fuel supply line and return fuel line should be tighten only after air bleeding 10 Defective copper s banjo washers should be replaced 11 Attain normal running
23. it on engine block 2 Defective oil sump packing should be replaced SEMESTER 4 DEISEL ENGINE SERVICE LAB 419 AUTOMOBILE ENGINEERING DEPT 3 Shellac should place towards sump side and grease on engine side of sump packing 4 Oil pump should be filled with oil before mounting it on engine 5 Gears and plate clearance should be as per manual instructions 6 If clearance between oil pump body and gear is more replace them 7 If there are lines groves scratches are appearing on gear plate grind it with fine emery paste and glass 8 Pressure should be adjusted through relief valve 9 Do not work with dirty hands 10 Oil sump bolts should not be over tightened because cork packing may get damage and oil may leak through it SEMESTER 4 DEISEL ENGINE SERVICE LAB 419 AUTOMOBILE ENGINEERING DEPT rm x s ahw SRE LOWE UAR ES DRIVE SEMESTER 4 DEISEL ENGINE SERVICE LAB 419 AUTOMOBILE ENGINEERING DEPT EXPERIMENT 7 SERVICING OF DIESEL FUEL FILTER ELEMENT PRE AND FINE Objective Dismantling Cleaning Checking Refitting and Bleeding Tools and Equipment Used Ring Spanner Set mm Double Ended Spanner Set mm and FlatScrewdriver 10 Raw Materials Required Cotton Waste Diesel Filters O Ring Procedure 1 We were given diesel filter assembly of Tata to service it 2 Dismounted filter assembly from vehicle by unthreading center bolts of fuel filter bowl 3 Cleaned filter bowl
24. led while fitting oil pump with engine 6 If outer rotor inner rotor outer body related data is not known refer workshop manual 7 Oil sump should be cleaned before mounting it 8 Oil sump packing should be replaced 9 Oil sump packing should be installed with shellac on sump side of the packing and grease on other side of it 10 Oil pump bolts should not be over tightened If we do so packing may be damaged and oil may leak from it Note 1 In some oil pumps there is no pressure relief valve is fitted while it is installed in oil gallery If pressure is to be adjusted may be adjusted with it 2 If oil pressure is low at low speed and high at high speed then do not overhaul oil pump and first adjust pressure through pressure relief valve If it does not works then overhaul pump SEMESTER 4 DEISEL ENGINE SERVICE LAB 419 AUTOMOBILE ENGINEERING DEPT ORIVEN GEAR INNER ROTOR R RETAINING PIN OUTER ROTOR RELIEF VALVE ASSEMBLY GASKET COVER BOLT vn gma PRESSURE RELIEF VALVE SPRING 0 PRESSURE RELIEF VALVE GASKET m i 6 PRESSURE RELIEF VALVE RETAINER between Checking Clearance between Checking Clearance Outer Rotor and Oil Pump Body Inner Rotor and Outer Rotor SEMESTER 4 DEISEL ENGINE SERVICE LAB 419 AUTOMOBILE ENGINEERING DEPT EXPERIMENT 6 OVERHAULING OF GEAR TYPE OIL PUMP Objective Removing Cleaning Checking Assembling and Refitting Tools and equipment Used Double Ended Spanner
25. n correct sequence to the specified torque use torque wrench Procedure e Turn the crank shaft in the clock wise direction and coincide the flywheels TDC 1 6 OR MARK WITH THE FLYWHEEL HOUSING POINTER Then ensure that the first cylinder is in compression stroke e Hold firmly the tappet adjusting screw with a god screw driver e Loosen the lock nut with a ring spanner e Insert a feeler guage of the specified thickness between the valve stem and rocker tip e Tighten the adjusting screw by a screw driver and at the same time move the feeler gauge to and fro e Stop tightening of the adjusting screw when the feeler gauge can be slide with a slight effort but it should not be jammed e Hold the adjusting screw in position with the screw driver firmly and tighten the lock nut by a ring spanner e Ensure that the adjusting screw does not turn by tightening by the lock nut e Check again the adjustment by sliding the feeler gauge leaf in the gap and turning the push rod e Repeat the above steps to adjust the tappet clearance for other valves bringing the respective positions on TDC of compression stroke according to firing stroke SEMESTER 4 DEISEL ENGINE SERVICE LAB 419 AUTOMOBILE ENGINEERING DEPT 1 Valve 3 Exhaust valve assembly 6 Spring 2 Wrench 4 Intake valve assembly 7 Feeler gauge 5 Rocker arm TS 6116 5 4 12 4 4 Lock Nut SEMESTER 4 DEISEL ENGINE SERVICE LAB 419 AUTOMOBILE ENGINEERING DEPT EXPERIMENT
26. radiator pressure cap This will allow air into the cooling system so that it can drain quickly and completely Open the drain valve so that the coolant can drain into the pan below When all the coolant has drained out close the drain valve 3 Refill coolant system Check the shop service manual for the capacity of the system and the recommended type and mixture of coolant for the operating conditions of the vehicle Measure the recommended amount of coolant and using a funnel pour it in through the top of the radiator 4 Start engine and verify Air can be trapped in the cooling system so leave the radiator cap off to allow it to escape and run the Engine for a few minutes to allow the coolant to circulate and get rid of trapped air Then replace theradiator cap and bring the engine up to operating temperature Check the coolant level in the reservoir and top it up to the high or hot engine mark 5 Dispose of waste Antifreeze is toxic so dispose of the waste coolant carefully and in an environmentally recommended way SEMESTER 4 DEISEL ENGINE SERVICE LAB 419 AUTOMOBILE ENGINEERING DEPT EXPERIMENT 9 ADJUSTING THE VALVE TAPPET CLEARANCE 4 CYLINDER 6 CYLINDER ENGINE OBJECTIVES e Adjust the valve tappet clearance in a 4 cylinder engine e Adjust the tappet clearance in a 6 cylinder engine e Adjust the tappet clearance in a side valve engine Job sequence PRILIMINARY OPERATIONS e Tighten all the cylinder head bolt nuts i
27. such as rubber gloves and barrier cream Respiratory equipment such as face masks and valved respirators If you are not certain what is appropriate or required ask your supervisor Safety check Never drain and refill the cooling system of a hot engine Wait for it to cool down first Always make sure that you wear the appropriate personal protection equipment before starting the job It is very easy to hurt yourself even when the most exhaustive protection measures are taken Always make sure that your work area environment is as safe as you can make it Do not use damaged broken or worn out workshop equipment Always follow any manufacturer s personal safety instructions to prevent damage to the vehicle you are servicing Make sure that you understand and observe all legislative and personal safety procedures when carrying out the following tasks If you are unsure of what these are ask your supervisor Points to note SEMESTER 4 DEISEL ENGINE SERVICE LAB 419 AUTOMOBILE ENGINEERING DEPT Some vehicles have drain plugs on the side of the engine block The shop service manual will tell you if these need to be opened when draining the coolant Part 2 Step by step instruction 1 Locate drain plug Locate the cooling system drain plug or valve on the bottom tank of the radiator Place a clean drain pan large enough to contain all the coolant underneath the drain valve 2 Drain radiator Carefully remove the
28. temperature of engine by keeping it running for five minutes and belt s tension should be checked PARTS Components of the fuel injection pump Lucas DP200 Series Table 9 1 O ring 8 Electrical connection for 2 Hub nutstop solenoid 3 Locking spacer 9 Fuel supply connection 4 Locking screw 10 Mounting flange 5 Low idle SEMESTER 4 DEISEL ENGINE SERVICE LAB 419 AUTOMOBILE ENGINEERING DEPT adjustment screw 11 The fuel discharge lines 6 High idle adjustmentthat supply fuel to thescrewfuel injector nozzles 7 Connection for the fuel 12 Screw for adjustment ofreturntiming advance 13 Fittings for fuel EXPERIMENT 3 OVERHAULING OF CYLINDER HEAD OF DIESEL ENGINE Objective Removing Decarbonizing Checking Grinding Valve Seats Injector Pressure Testing and Refitting Tools and Equipment Used Ring Spanner Set inch Socket Set inch Double Ended Spanner Set inch Flat Screwdriver 8 amp 10 Plier 6 injector Extractor Valve Spring Compressor Valve Grinding Stick Feeler Gauge Torque Wrench Injector Testing Machine Surface Plate etc Raw Material Required Cylinder Head Gasket Top over Hauling Kit Valve Grinding Paste Kerosene Oil Diesel Petrol Engine Oil 20W 40 Emery Paper Old Dhoti Water and Coolant Procedure we were given an engine of ambassador which was stand mounted to overhaul its cylinder head 1 Dismounting Cylinder Head i Drained out all water coolant from engin
29. th does not have any marks 15 Checked valve seat of feed pump that too was OK SEMESTER 4 DEISEL ENGINE SERVICE LAB 419 AUTOMOBILE ENGINEERING DEPT 16 Check hand priming pump with vacuum method Keep thumb or a little pressure over threaded part and pulled hand pump If piston of priming pump remains lifted it shows there is a leakage and if after pulling up the pump settles a little down then it is OK 17 Rested feed pump s plunger in its body and checked for its loosening and also checked it using vacuum method 18 Checked tappet roller and its pin for their worn out Assembling 1 Rested pump plunger return spring pump housing Mounted new copper washer and tighten screw plug 30mm using ring spanner 2 Rested roller spring tappet roller assembly in housing and locked it using plier 3 Placed inlet and outlet valve at their seat and placed and hand priming pump over inlet 4 Tighten outlet screw plug with new copper washer over outlet valve 5 Mounted new filter housing rubber cleaned nylon filter and spring in filter housing and tighten clamping nut by threading it with fingers Testing 1 Tighten flexible diesel pipe to inlet with banjo bolt 2 Immersed the other end in diesel filled jar and moved hand priming pump up and down Outlet supply was quite regular 3 Mounted feed pump with new packing over pump by threading all three flange nuts 4 Mounted new washer in banjo bolt of fu
30. the engine block thoroughly for minute cracks and inspect visually to detect cracks and if needed use a magnetic crack detector e Check for water leakage with a dummy cover and water under pressure Replace the block if any water leakage is discovered SEMESTER 4 DEISEL ENGINE SERVICE LAB 419 AUTOMOBILE ENGINEERING DEPT e Check the flatness of the machined top and bottom surface of the cylinder block with a straight edge and feeler gauge e Inspect the parent bore of the cylinder block for in line alignment using line boring bar straight edge e Measure the main bearing parent bore using a bore dial gauge for taper and ovality e Measure the cylinder bore diameter for wear taper and ovality e Remove the cylinder liners e Refit the liners e Insome engines liners not used reboring of cylinder block is recommended by the manufacture follow the manufactures recommendations INSPECTION OF FLYWHEEL CRANKSHAFT CAMSHAFT AND TIMING GEAR AND SPROCKETS AND CHAIN e Check visually the flywheel surface for cracks burnt and scored face e Check the warpage of the flywheel friction surface by using a straight edge if the warpage is morethan the maximum limit specified by the manufacturer then the flywheel should be reground Ensure that after regrinding the flywheel thickness is not reduced below the minimum limit specified by the manufacturer e Mount the fly wheel on the crank shaft and keep it on the inspection table e Note down the f
31. tributor drive gear Support the camshaft and carefully side into position through the camshaft bearings ensure that the cam lobes do not touch the bearings Fit the thrust plate and tighten retaining bolts to the specified torque SEMESTER 4 DEISEL ENGINE SERVICE LAB 419 AUTOMOBILE ENGINEERING DEPT EXPERIMENT 11 OVERHAULING THE PISTON AND CONNECTING ROD ASSEMBLY Main Bearing Camshafi End Cap Comecting Rod Crankshali Beanng OBJECTIVES e REMOVE THE RINGS FROM THE PISTON DISMANTLE THE PISTON AND CONNECTING ROD e CHECK THE SIDE CLEARANCE OF THE RINGS IN THE PISTON GROOVE e MEASURE THE PISTON RINGS CLOSE GAP IN THE CYLINDER WITH A FEELER GAUGE e MEASURE THE CLEARANCE BETWEEN THE PISTON AND THE LINER e MEASURE THE PISTON DIAMETER AT DIFFERENT POINTS e MEASURE THE CLEARANCE BETWEEN THE CRANKPIN AND THE CONNECTINGROD BIG END BEARING WITH A MICROMETER AND A BORE DIAL GAUGE e MEASURE THE CYLINDER LINER FOR WEAR TAPER OVALITY WITH A MICROMETER AND A BORE DIAL GAUGE e CHECK THE CONNECTING RODS ALIGNMENT e ASSEMBLE THE PISTON WITH THE CONNECTING ROD SEMESTER 4 DEISEL ENGINE SERVICE LAB 419 AUTOMOBILE ENGINEERING DEPT e ASSEMBLE THE RINGS IN THE PISTON CORRECTLY JOB SEQUENCE DISMANTLING e HOLD THE CONNECTING ROD ON THE VICE e REMOVE THE RINGS FROM THE PISTON WITH THE HELP OF A RING EXPANDER e REMOVE THE CIRCLIP OF THE PISTON PIN USING A CIRCLIP PLIER e REMOVE THE PISTON PIN WITH HELP OF DRIFT AND HAMMER RO
32. with diesel after taking the element out from it 4 Cleaned pre filter with the help of cleaning brush and blown out the inside dirt of both filters 5 Placed pre and fine filter elements in their respective bowl and filled both bowls with diesel Tightened to cover plate over it 6 Tightened central clamping bolts 7 First bleed the pre filter followed by fine filter by pumping with the help of hand priming and feed pump 8 Bleed F Pump after bleeding of both filters 9 Cranked and then started engine Checked it for air bubbling Starting was up to the mark and there was no missing too Precautions 1 Fuel filter bowls should be fitted by rotating them 2 After cleaning of filter element slight air pressure should be applied to them 3 Air vent screws should be tighten only after pressing the hand priming 4 Air vent screws should not be over tighten 5 Bleeding should be done until there is continuous flow of diesel 6 Pump should be bleed after filters 7 New rubber O ring should be used while servicing fuel filters and it should be fitted properly in respective seat 8 All bleeding screws banjo bolts their washers should be checked thoroughly and replace if required 9 Fuel feed pump s filter element and its bowl should also be cleaned while performing the operation SEMESTER 4 DEISEL ENGINE SERVICE LAB 419 AUTOMOBILE ENGINEERING DEPT 10 Do not work with dirty hands CLAMP
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